KR102609338B1 - porous abrasive articles - Google Patents

Abstract

An abrasive article comprising an adhesive layer and an abrasive layer. The adhesion layer includes a first major surface, an opposing second major surface, and a porous backing having a first plurality of voids extending from the first major surface to the second major surface. The abrasive layer includes a cured composition having a third major surface and an opposing fourth major surface, abrasive particles at least partially embedded within the cured composition, and a second plurality of voids extending from the third major surface to the fourth major surface. Includes. The first major surface of the adhesion layer is adjacent the third major surface of the polishing layer, and the pattern of the second plurality of voids is independent of the pattern of the first plurality of voids.

Description

porous abrasive articles

It is very common for dry sanding operations to generate significant amounts of airborne dust. To minimize this airborne dust, it is common to use an abrasive disk on the tool while drawing a vacuum through the abrasive disk, from the abrasive side of the disk through the back, and into a dust-collection system. For this purpose, a number of abrasives are available with holes drilled into them to facilitate extraction of this dust. As an alternative to drilling dust-extraction holes in an abrasive disc, commercial products exist in which the abrasive is coated on the fibers of a net-type knitted backing in which the loops are knitted to the back of the abrasive article. The loop serves as the loop portion of a hook-and-loop attachment system for attachment to the tool. Coating the abrasive only on the fibers of the net-like backing results in a very low percentage of abrasive area on the abrasive disc. As a result, the grinding performance (cutting and/or life) of this type of abrasive is low compared to conventional abrasives with dust-extraction holes. Net-type products are known to provide excellent dust extraction and/or anti-loading properties when used with substrates known to heavily load traditional abrasives. However, cutting and/or life performance are still lacking. Accordingly, there is a need for a net-type product that provides improved cutting and/or lifetime performance while exhibiting excellent dust extraction.

The drawings generally illustrate the various embodiments discussed herein by way of example and not by way of limitation.
1 is a perspective view of an abrasive article according to various embodiments of the present invention.
Figure 2 is a side cross-sectional view of an abrasive article according to various embodiments of the present invention.
3A and 3B are top views of an abrasive article according to various embodiments of the present invention.
4A and 4B are top views of an abrasive article according to various embodiments of the present invention.
Figure 5 is a side cross-sectional view of an abrasive article according to various embodiments of the present invention.
6 and 7 are side cross-sectional views of an abrasive article according to various embodiments of the present invention.
Figure 8 is a plot of the surface topography of Mesh Backing 1, Example 3, and Comparative Example B of the present invention.
It should be understood that many other variations and examples may be devised by those skilled in the art that fall within the scope and spirit of the principles of the present invention. Drawings may not be drawn to a certain scale.

Embodiments described herein relate to abrasive articles that exhibit the polishing performance (cut and/or life) advantages of conventional abrasives while maintaining the dust-extraction advantages of abrasives on a net-type backing. This combination of advantages (dust extraction and cutting and/or life) is possible because the abrasive is pattern-coated to form well-defined areas of the abrasive coating as well as open areas without any abrasive coating. Because the abrasive coating is not limited to the fibers of the knitted backing, the patterned abrasive zone can be designed independently of the netted knitted backing to optimize both abrasive performance and dust extraction.

Referring to Figure 1, an embodiment of an abrasive article of the present invention includes an abrasive article designated at 100. The abrasive article 100 includes an adhesion layer 110 further comprising a porous backing layer 160 having a first major surface 102 and an opposing second major surface 104; and an abrasive layer 120 having a third major surface 122 and an opposing fourth major surface 124. The porous backing layer 160 has a first plurality of pores 140 (phantom lines) extending from the first major surface 102 to the second major surface 104 of the porous backing layer 160 and forming a first pattern. Includes. In some embodiments, attachment layer 110 may include one part of a two-part interconnect attachment mechanism. The two-part interconnection attachment mechanism may be a hook-and-loop two-part interconnection attachment mechanism. In some embodiments, one part of the two-part interconnection attachment mechanism may be a hook portion of a hook-loop two-part interconnection attachment mechanism. In some embodiments, one part of the two-part interconnection attachment mechanism may be a loop portion of a hook-loop two-part interconnection attachment mechanism. In some embodiments, the porous backing layer 160 of attachment layer 110 may include one part of a two-part interconnection attachment mechanism, such as a hook-loop attachment mechanism. The loop portion of the two-part interconnect attachment mechanism is integral to the porous backing layer 160. Optionally, attachment layer 110 may include one part of a two-part interconnection attachment mechanism layer 150. Optionally one part of the two-part interconnect attachment mechanism layer 150 may be positioned adjacent the second major surface 104 of the porous backing layer 160. Abrasive layer 120 includes a cured composition and abrasive particles at least partially embedded within the cured composition; and a second plurality of voids 130 that are free of the cured composition and extend from the third major surface 122 to the fourth major surface 124 and form a second pattern independent of the first pattern. The first major surface 102 of the porous backing layer 160 is adjacent the third major surface 122 of the polishing layer. In some embodiments, polishing layer 120 is a continuous polishing layer. In some embodiments, abrasive layer 120 is a continuous abrasive layer, and an optional part of two-part interconnect attachment mechanism layer 150 is not utilized.

In some examples, the abrasive articles of various embodiments described herein have a pressure of about 1.0 L/s, 1.5 L/s, 2.0 L/s, 2.5 L/s, such that dust can be removed from the polished surface through the abrasive article when in use. or even air flow through the article at a velocity greater than 3.0 L/s.

As used herein, with reference to continuous polishing layer 120, the term "continuous" generally refers to a line, e.g., line L and line L', as shown in Figure 4A, which is an edge of polishing layer 120. This means that it can be traced from 108 to another edge 112 and then to edges 108 and 112'. In other words, the polishing layer 120 is striped and uninterrupted as shown in FIG. 4B.

FIG. 2 shows a cross-section of the abrasive article designated at 100 taken on line 2-2 in FIG. 1 looking in the direction of the arrow. As shown in FIG. 2 , the abrasive article 100 has a porous backing layer 160 having a first major surface 102 and an opposing second major surface 104. It includes an adhesion layer 110 comprising. Porous backing layer 160 includes a first plurality of voids 140 that extend from first major surface 102 to second major surface 104 of porous backing layer 160 and form a first pattern. In some embodiments, porous backing layer 160 may be part of a two-part interconnection attachment mechanism, i.e., one part of the two-part interconnection attachment mechanism is integral to porous backing layer 160. Optionally, attachment layer 110 may include one part of a two-part interconnection attachment mechanism layer 150. Optionally one part of the two-part interconnect attachment mechanism layer 150 may be positioned adjacent the second major surface 104 of the porous backing layer 160. The abrasive article 100 further includes an abrasive layer 120 (e.g., a continuous abrasive layer) having a third major surface 122 and an opposing fourth major surface 124, wherein the abrasive layer is hardened. abrasive particles 106 at least partially embedded within the cured composition 125 and the cured composition, the cured composition extending from the third major surface 122 to the fourth major surface 124 and a first pattern and includes a second plurality of voids 130 forming a second independent pattern, and the first major surface 102 of the porous backing layer 160 is adjacent the third major surface 122 of the polishing layer.

In some embodiments, at least one of the plurality of voids 130 and the plurality of voids 140 forms a regular pattern. Figure 3A shows a regular pattern of voids 130 that may be formed in the abrasive layer 120 and a regular pattern of voids 140 that may be formed in the adhesion layer 110, while Figure 3B shows a regular pattern of voids 130 that may be formed in the abrasive layer 120. An irregular pattern of voids 130 that may be formed in 120 and a regular pattern of voids 140 that may be formed in adhesion layer 110 are shown. In some embodiments, both plurality of voids 130 and plurality of voids 140 form an irregular pattern.

1, 3A and 3B show voids 130, 140 having a substantially circular shape and void 130 being generally larger than void 140, the void may be of any suitable shape (e.g., rectangular). (oblong, square, triangle, diamond, etc.) and can have any suitable size. Additionally, not all voids 130 completely overlap with the void 140. 2, 3A, and 3B, in some embodiments, voids 130 may completely overlap voids 140, although not all voids 130 need to overlap voids 140. does not exist. However, as those skilled in the art will appreciate, a greater percentage of overlap between voids 130 and voids 140 will result in dust-extraction advantages for the abrasive articles described herein.

In some embodiments, the abrasive layer 120 covers no more than about 40%, no more than about 50%, no more than about 60%, no more than about 70%, no more than about 80%, Covers less than about 90%, less than 95%, or even less than about 98%. In some embodiments, abrasive layer 120 covers about 50% to about 98%, about 50% to about 95%, about 50% to about 90%, about 50% to about 85%, about 50% to about 80%, about 60% to about 98%, about 60% to about 95%, about 60% to about 90%, about 60% to about 85%, about 60% Covers from about 80%, about 70% to about 98%, about 70% to about 95%, about 70% to about 90%, about 70% to about 85% or even about 70% to about 80%. In some cases, this means that the edge of the abrasive layer 120 substantially overlaps the edge of the adhesion layer 110, as shown in FIG. 3 means that the major surface 122 covers no more than 98% of the first major surface 102 of the adhesion layer 110.

In some embodiments, the surface topography of the fourth major surface 124 comprising abrasive particles 106 is independent of the topography of the first major surface 102 of the adhesion layer 110. In other words, even if the topography of the first major surface 102 of the adhesion layer 110 is “wavy” as shown in FIG. 5, the surface topography of the fourth major surface 124 is substantially can be flat and need not/do not follow the wavy topography of the first major surface 102 of the adhesion layer 110.

As used herein, the term “at least partially embedded” generally means that at least a portion of the abrasive particles are embedded within the cured composition such that the abrasive particles are secured within the cured composition.

Figure 6 is shown at 200, comprising a size coat 202 having all the features shown in Figure 2 (which will not be discussed again for brevity) as well as a size coat void space 203. An example of the referred abrasive article is shown.

In some embodiments, the abrasive articles of various embodiments described herein can have a supersize coat in addition to the size coat 202. FIG. 7 has all the features shown in FIG. 2 (which will not be discussed again for brevity) as well as a size coat 202 with a size coat void space 203 and a supersize coat void space 205. An abrasive article is shown, designated at 300, comprising a supersize coat 204.

Optionally, although not shown, any of the elements described herein to help adhere layers together, provide a printed image, act as a barrier layer, or serve any other purpose known in the art. One or more additional layers may be disposed between the layers. However, it should be understood that the layer configurations described herein are not intended to be exhaustive, and that layers may be added or removed with respect to any of the examples shown in FIGS. 1-7.

The abrasive layer of the abrasive articles of various embodiments described herein includes a curable composition. Upon curing, the curable composition is referred to as the cured composition. In some embodiments, the cured composition includes at least one of a cured epoxy-acrylate resin composition and a cured phenolic resin composition.

In some embodiments, the curable composition includes a phenolic resin composition. Useful phenolic resins include novolac phenolic resins and resol phenolic resins. Novolac phenolic resins are acid-catalyzed and are characterized by a formaldehyde to phenol ratio of less than 1, typically 0.5:1 to 0.8:1. Resole phenol resins are alkali catalyzed and are characterized by a ratio of formaldehyde to phenol of at least 1, typically 1:1 to 3:1. Novolac and resol phenolic resins may be chemically modified (e.g., by reaction with an epoxy compound) or they may be unmodified. Examples of acidic catalysts suitable for curing the phenolic resin to produce the cured phenolic resin composition included in the polishing layer include sulfuric acid, hydrochloric acid, phosphoric acid, oxalic acid, and p-toluenesulfonic acid. Alkaline catalysts suitable for curing phenolic resins include sodium hydroxide, barium hydroxide, potassium hydroxide, calcium hydroxide, organic amines, or sodium carbonate.

Phenolic resins are well known and readily available from commercial sources. Examples of commercially available novolac resins include DUREZ 1364, a two-step, powdered phenolic resin (sold under the trademark VARCUM by Durez Corporation, Addison, Texas). For example, 29302), or HEXION AD5534 RESIN (available from Hexion Specialty Chemicals, Inc., Lewisville, KY). . Examples of commercially available resol phenolic resins useful in the practice of the present invention include those sold under the trademark Barkum by Durez Corporation, Addison, Texas (e.g., 29217, 29306, 29318, 29338, 29353); those sold under the trade name AEROFENE by Ashland Chemical Co., Bartow, Fla. (e.g., AEROFENE 295); and those sold under the trade name “PHENOLITE” by Kangnam Chemical Company Ltd., Seoul, Korea (e.g., Phenolite TD-2207).

In another embodiment, the curable composition includes a polymerizable epoxy-acrylate resin composition. In some embodiments, the polymerizable epoxy-acrylate resin composition has a complex viscosity of about 10 Pa-s to about 10,000 Pa-s at 125° C. and 1 Hz frequency; Abrasive particles are at least partially embedded within the polymerizable epoxy-acrylate resin composition. In some specific examples, the cured composition/polishing layer is a photopolymerization product of a curable composition. In some examples, the cured polymerizable epoxy-acrylate resin composition has a storage modulus (G') of at least about 300 MPa at 25°C and 1 Hz frequency. And, in some cases, in addition to having a complex viscosity of about 10 Pa-s to about 10,000 Pa-s at 125°C and 1 Hz frequency, the curable composition may also have a complex viscosity of about 1,000 Pa-s at 25°C and 1 Hz frequency. to about 100,000 Pa-s.

In some embodiments, the curable composition has a complex viscosity at 125°C and 1 Hz frequency of at least about 10 Pa-s, at least about 50 Pa-s, at least about 100 Pa-s, at least about 1,000 Pa-s, and about 2,000 Pa-s. s or greater, about 3,000 Pa-s or greater, about 5,000 Pa-s or greater, or about 6,000 Pa-s or greater. In some examples, the polymerizable epoxy-acrylate resin composition has a complex viscosity of about 1,000 Pa-s or less, about 2,000 Pa-s or less, about 3,000 Pa-s or less, about 5,000 Pa-s or less at 125°C and 1 Hz frequency. , about 6,000 Pa-s or less, about 8,000 Pa-s or less, or about 10,000 Pa-s or less. In another example, the polymerizable epoxy-acrylate resin composition has a complex viscosity of about 10 Pa-s to about 10,000 Pa-s, about 1000 Pa-s to about 8000 Pa-s, about 2000 at 125°C and 1 Hz frequency. Pa-s to about 5,000 Pa-s, about 500 Pa-s to about 3,000 Pa-s, about 2,000 Pa-s to about 7000 Pa-s or about 3,000 Pa-s to about 10,000 Pa-s.

In some examples, the polymerizable epoxy-acrylate resin composition also has a complex viscosity of at least about 1000 Pa-s, at least about 4000 Pa-s, at least about 8000 Pa-s, and about 10,000 Pa-s at 25°C and 1 Hz frequency. or more, about 12,000 Pa-s or more, about 20,000 Pa-s or more, about 50,000 Pa-s or more, or about 80,000 Pa-s or more. In some examples, the polymerizable epoxy-acrylate resin composition has a complex viscosity of about 100,000 Pa-s or less, about 10,000 Pa-s or less, about 12,000 Pa-s or less, about 15,000 Pa-s or less at 25°C and 1 Hz frequency. , about 30,000 Pa-s or less, about 50,000 Pa-s or less, or about 80,000 Pa-s or less. In another example, the polymerizable epoxy-acrylate resin composition has a complex viscosity at 25° C. and 1 Hz frequency of about 1000 Pa-s to about 100,000 Pa-s, about 1000 Pa-s to about 8000 Pa-s, about 6000 Pa-s to about 15,000 Pa-s, about 8000 Pa-s to about 30,000 Pa-s, about 20,000 Pa-s to about 80,000 Pa-s, or about 30,000 Pa-s to about 60,000 Pa-s.

In some examples, the polymerizable epoxy-acrylate resin composition has a storage modulus (G') of at least about 5,000 Pa, at least about 20,000 Pa, at least about 30,000 Pa, or at least 40,000 Pa at 25°C and 1 Hz frequency. In some examples, the polymerizable epoxy-acrylate resin composition has a G' of less than or equal to about 20,000 Pa, less than or equal to about 30,000 Pa, less than or equal to about 40,000 Pa, or less than or equal to about 50,000 Pa at 25°C and 1 Hz frequency. In another example, the polymerizable epoxy-acrylate resin composition has a G' of about 5000 Pa to about 10,000 Pa, 10,000 Pa to about 50,000 Pa, about 20,000 Pa to about 40,000 Pa, about 25,000 Pa at 25°C and 1 Hz frequency. to about 40,000 Pa or about 25,000 Pa to about 35,000 Pa.

In some examples, the polymerizable epoxy-acrylate resin composition has a loss modulus (G") of at least about 5,000 Pa, at least about 20,000 Pa, at least about 30,000 Pa, or at least 40,000 Pa at 25° C. and 1 Hz frequency. In some examples, , the curable composition has a G" of less than or equal to about 20,000 Pa, less than or equal to about 30,000 Pa, less than or equal to about 40,000 Pa, or less than or equal to about 50,000 Pa at 25° C. and a frequency of 1 Hz. In another example, the curable composition has a G" of from about 5000 Pa to about 10,000 Pa, from 10,000 Pa to about 50,000 Pa, from about 20,000 Pa to about 40,000 Pa, from about 25,000 Pa to about 40,000 Pa, or about 25,000 Pa to about 35,000 Pa.

In some examples, a 10 cm It is about 300 MPa or more, about 400 MPa or more, about 600 MPa or more, or about 800 MPa or more. In some examples, the cured polymerizable epoxy-acrylate resin composition has a G' of less than or equal to about 400 MPa, less than or equal to about 500 MPa, or less than or equal to about 950 MPa. In some examples, a 10 cm x 5 cm x 0.07 mm film formed from a cured polymerizable epoxy-acrylate resin composition (however, the film may be of any suitable dimension) has a G' of from about 300 MPa to about 950 MPa. ; about 400 MPa to about 800 MPa; or about 300 MPa to about 600 MPa.

In some examples, a 10 cm At least about 100 MPa, at least about 200 MPa, at least about 250 MPa, or at least about 350 MPa. In some examples, the cured polymerizable epoxy-acrylate resin composition has a G" of at least about 200 MPa, at least about 300 MPa, or It is about 400 MPa or less. In some examples, a 10 cm ; about 100 MPa to about 200 MPa; or about 150 MPa to about 250 MPa.

Complex viscosity, G' and G" measurements were performed using a TA Instruments Discovery instrument equipped with a disposable 8 mm diameter aluminum parallel plate geometry, which directly probes the viscoelastic properties of the polymer and generates time-temperature-superposition (TTS) curves. ) can be obtained using a HR-2 rheometer. Measurements can be performed at a constant nominal strain value within the linear viscoelastic regime, determined by a strain sweep (0.004 to 2.0% oscillatory strain) at 1 Hz. Temperature-step, frequency-sweep experiments were performed at 10°C/step. Using the time-temperature superposition method, the frequency dependence can be investigated over a wide frequency range. G' and G" obtained for each polymer. can be moved using the TA Instruments TRIOS software package and the horizontal translation factor (aT). A master curve based on the shift and overlap of both G' and G" yielded a horizontal shift factor, which can be fit to the WLF equation using TRIOS. G' and G" and complex viscosity values were then calculated at 25°C. and 1 Hz frequency.

However, in some embodiments, a film formed from curing a polymerizable epoxy-acrylate resin composition (e.g., 38 mm × 50 mm × 0.50 or 0.70 mm film, but the film may be of any suitable dimension, has a stiffness of about 0.01 to about 0.5 N-mm (e.g., about 0.01 to about 0.1 N-mm, about 0.05 to about 0.1 N-mm). mm or about 0.05 to about 0.09 N-mm).

In some examples, a film formed from curing a polymerizable epoxy-acrylate resin composition, having a plurality of voids without the polymerized epoxy-acrylate resin composition (e.g., a 38 mm × 50 mm × 0.50 or 0.70 mm film, However, the film may be of any suitable dimension) has a stiffness of less than or equal to about 0.5 N-mm, less than or equal to about 0.3 N-mm, less than or equal to about 0.2 N-mm, or less than or equal to about 0.2 N-mm, as determined using the methods described herein. 0.1 N-mm or less or about 0.09 N-mm or less. In some examples, the cured polymerizable epoxy-acrylate resin composition having a plurality of voids free of the polymerized epoxy-acrylate resin composition has a stiffness of at least about 0.01 N-mm, at least about 0.05 N-mm, and at least about 0.09 N. -mm or more; It is about 0.1 N-mm or more or about 0.2 N-mm or more. In some examples, the cured polymerizable epoxy-acrylate resin composition having a plurality of voids free of the polymerized epoxy-acrylate resin composition has a stiffness of about 0.01 to about 0.5 N-mm (e.g., about 0.01 to about 0.5 N-mm). 0.1 N-mm, about 0.05 to about 0.1 N-mm or about 0.05 to about 0.09 N-mm).

In some examples, a film formed from curing a polymerizable epoxy-acrylate resin composition, having a plurality of voids without the polymerized epoxy-acrylate resin composition (e.g., a 38 mm × 50 mm × 0.50 or 0.70 mm film, However, the film may be of any suitable dimension) having a bending force of less than or equal to about 1.5 N, less than or equal to about 0.7 N, less than or equal to about 0.5 N, or less than or equal to about 0.3 N. N or less or about 0.1 N or less. In some examples, the cured polymerizable epoxy-acrylate resin composition having a plurality of voids free of the polymerized epoxy-acrylate resin composition has a bending force of at least about 0.2 N, at least about 0.5 N, at least about 0.7 N; It is about 0.9 N or more or about 1.0 N or more. In some examples, the cured polymerizable epoxy-acrylate resin composition, having a plurality of voids free of the polymerized epoxy-acrylate resin composition, has a bending force of about 0.1 to about 1.5 N (e.g., about 0.2 to about 0.9 N). N, about 0.3 to about 0.5 N or about 0.4 to about 0.9 N).

In some examples, a film formed from curing a polymerizable epoxy-acrylate resin composition, having a plurality of voids without the polymerized epoxy-acrylate resin composition (e.g., a 38 mm × 50 mm × 0.50 or 0.70 mm film, However, the film may be of any suitable dimension) having a force after holding time of less than or equal to about 1.5 N, less than or equal to about 0.7 N, or less than or equal to about 0.5 N, as determined using the methods described herein. or less, about 0.3 N or less, or about 0.1 N or less. In some examples, the cured polymerizable epoxy-acrylate resin composition having a plurality of voids free of the polymerized epoxy-acrylate resin composition has a force after a holding time of at least about 0.2 N, at least about 0.5 N, at least about 0.7 N. ; It is about 0.9 N or more or about 1.0 N or more. In some examples, the cured polymerizable epoxy-acrylate resin composition, having a plurality of voids free of the polymerized epoxy-acrylate resin composition, has a force after a holding time of about 0.1 to about 1.5 N (e.g., about 0.2 to about 1.5 N). about 0.9 N, about 0.3 to about 0.5 N, or about 0.4 to about 0.9 N).

In some examples, a film formed from curing a polymerizable epoxy-acrylate resin composition, having a plurality of voids without the polymerized epoxy-acrylate resin composition (e.g., a 38 mm × 50 mm × 0.50 or 0.70 mm film, However, the film may be of any suitable dimension) having a maximum force, as determined using the methods described herein, of less than or equal to about 1.5 N, less than or equal to about 0.7 N, less than or equal to about 0.5 N, or less than or equal to about 0.3 N. N or less or about 0.1 N or less. In some examples, the cured polymerizable epoxy-acrylate resin composition having a plurality of voids free of the polymerized epoxy-acrylate resin composition has a maximum force of at least about 0.2 N, at least about 0.5 N, at least about 0.7 N; It is about 0.9 N or more or about 1.0 N or more. In some examples, the cured polymerizable epoxy-acrylate resin composition, having a plurality of voids free of the polymerized epoxy-acrylate resin composition, has a maximum force of about 0.1 to about 1.5 N (e.g., about 0.2 to about 0.9 N). N, about 0.3 to about 0.5 N or about 0.4 to about 0.9 N).

Components useful in the curable composition used to prepare the cured composition included in the polishing layer are listed and described in more detail herein. In some examples, the curable compositions of various embodiments described herein include i) about 15 to about 50 parts by weight of a THF (meth)acrylate copolymer component; ii) about 25 to about 50 parts by weight of one or more epoxy resins; iii) about 5 to about 15 parts by weight of at least one hydroxy-functional polyether; iv) at least one polyhydroxyl-containing compound in the range of about 10 to about 25 parts by weight, wherein the sum of i) to iv) is 100 parts by weight; and v) from about 0.1 to about 5 parts by weight of a photoinitiator per 100 parts of i) to iv).

In some embodiments, the polymerizable epoxy-acrylate resin component included in the curable composition includes a tetrahydrofurfuryl (THF) (meth)acrylate copolymer component; One or more epoxy resins; and one or more hydroxy-functional polyethers.

The tetrahydrofurfuryl (THF) (meth)acrylate copolymer component is formed from a polymerizable mixture. Unless otherwise specified, THF acrylates and methacrylates will be abbreviated as THFA. More specifically, the curable composition comprises one or more tetrahydrofurfuryl (meth)acrylate monomers, one or more C ₁ -C ₈ (meth)acrylate ester monomers, one or more optional cationically reactive functional (meth)acrylate monomers, A THFA copolymer component formed from a polymerizable composition comprising at least one chain transfer agent and at least one photoinitiator.

The THFA copolymer component includes C ₁ -C ₈ alkyl (meth)acrylate ester monomers. Useful monomers include the acrylates and methacrylates of methyl, ethyl, propyl, isopropyl, butyl, pentyl, hexyl, heptyl and octyl alcohol, including all isomers and mixtures thereof. In some embodiments, the alcohol is selected from C ₃ -C ₆ alkanols, and in certain embodiments, the alkanol has a molar carbon number average of C ₃ -C ₆ . Within this range, the copolymer was found to have sufficient miscibility with the epoxy resin components described herein.

Additionally, the THFA copolymer component may contain cation-reactive monomers (e.g., (meth)acrylate monomers with cation-reactive functional groups). Examples of such monomers include, for example, glycidyl acrylate, glycidyl methacrylate, hydroxyethyl acrylate, hydroxyethyl methacrylate, hydroxypropyl methyl acrylate, hydroxybutyl acrylate and alkoxy Silylalkyl (meth)acrylates such as trimethoxysilylpropyl acrylate are included.

In some embodiments, the copolymer is formed from a polymerizable mixture that includes, among other things, one or more chain transfer agents that function to control the molecular weight of the resulting THFA copolymer component. Examples of useful chain transfer agents include, but are not limited to, carbon tetrabromide, alcohols, mercaptans such as isooctylthioglycolate, and mixtures thereof. If used, the polymerizable mixture may include up to 0.5% by weight chain transfer agent based on the total weight of polymerizable materials. For example, the polymerizable mixture may contain 0.01 to 0.5 weight percent, 0.05 to 0.5 weight percent, or 0.05 to 0.2 weight percent chain transfer agent.

In some embodiments, the THFA copolymer component is essentially free of acid functional monomers, the presence of which can initiate polymerization of the epoxy resin prior to UV curing of the curable composition. In some embodiments, the copolymer also does not contain any amine-functional monomers. Additionally, in some embodiments, the copolymer does not contain any acrylic monomers with moieties that are sufficiently basic to inhibit cationic curing of the curable composition.

THFA copolymers generally include (A) 40 to 60% by weight (e.g., 50 to 60% and 45 to 55% by weight) of tetrahydrofurfuryl (meth)acrylate; (B) 40 to 60 wt.% (e.g., 40 to 50 wt.% and 45 to 55 wt.%) of C ₁ -C ₈ (e.g., C ₃ -C ₆ ) alkyl (meth)acrylate ester monomer ; and (C) 0 to 10 weight percent (e.g., 1 to 5 weight percent, 0 to 5 weight percent, and 0 to 2 weight percent) of polymerized monomer units of a cationically reactive functional monomer, wherein: The sum of A) to C) is 100% by weight.

The curable compositions of various embodiments described herein may include one or more THFA copolymers in varying amounts, depending on the desired properties of the abrasive layer (cured and/or uncured). In some embodiments, the curable composition includes one or more THFA copolymers in an amount of 15 to 50 parts by weight (e.g., 25 to 35 parts by weight) based on 100 parts by total weight of monomers/copolymers in the curable composition.

The curable composition may include one or more thermoplastic polyesters. Suitable polyester components include semi-crystalline polyesters as well as amorphous and branched polyesters. However, in some embodiments, the curable compositions of various embodiments described herein are substantially free of thermoplastic polyester; Contains trace amounts or less of thermoplastic polyester; Alternatively, it is contained in an amount that will not substantially affect the properties of the curable composition.

Thermoplastic polyesters may include hydroxyl- and carboxyl-terminated polyesters and polycaprolactone, and may be amorphous or semi-crystalline at room temperature. In some embodiments, the polyester is a hydroxyl terminated polyester that is semicrystalline at room temperature. A material that is “amorphous” has a glass transition temperature, but does not exhibit a measurable crystalline melting point as determined by differential scanning calorimetry (“DSC”). In some embodiments, the glass transition temperature is less than about 100°C. Materials that are “semi-crystalline” exhibit a crystalline melting point as determined by DSC, and in some embodiments have a maximum melting point of about 120°C.

Crystallinity in a polymer can also be reflected by clouding or opacity when a sheet heated to an amorphous state is cooled. When the polyester polymer is heated to a molten state and knife-coated onto a liner to form a sheet, it is observed that the polyester polymer is amorphous and the sheet is transparent and highly transmissive to light. As the polymer within the sheet material cools, crystalline domains form and crystallization is characterized by clouding of the sheet to a translucent or opaque state. Crystallinity can be varied in the polymer by mixing amorphous and semi-crystalline polymers of varying crystallinity in any compatible combination. It is generally desirable to allow a material heated to an amorphous state to sit for a sufficient time to return to its semi-crystalline state prior to use or application. Opacification of the sheet provides a convenient, non-destructive method of determining the extent to which such crystallization has occurred in the polymer.

Polyesters may contain nucleating agents to increase the rate of crystallization at a given temperature. Useful nucleating agents include microcrystalline waxes. Suitable waxes include alcohols containing a carbon chain with a length of more than 14 carbon atoms (CAS #71770-71-5) or UNILIN™ 700 by Baker Hughes, Houston, TX. Ethylene homopolymer (CAS #9002-88-4) sold as:

In some embodiments, the polyester is solid at room temperature. The polyester may have a number average molecular weight of about 7,500 g/mol to 200,000 g/mol (e.g., about 10,000 g/mol to 50,000 g/mol and about 15,000 g/mol to 30,000 g/mol).

Polyesters useful for use in the curable compositions of various embodiments described herein include the reaction product of a dicarboxylic acid (or diester equivalent thereof) with a diol. A diacid (or diester equivalent) is a saturated aliphatic acid containing 4 to 12 carbon atoms (including branched, unbranched, or cyclic materials with 5 to 6 carbon atoms in the ring) and/or It may be an aromatic acid containing 8 to 15 carbon atoms. Examples of suitable aliphatic acids are succinic acid, glutaric acid, adipic acid, pimelic acid, suberic acid, azelaic acid, sebacic acid, 1,12-dodecanedioic acid, 1,4-cyclohexanedicarboxylic acid, 1 , 3-cyclopentanedicarboxylic acid, 2-methylsuccinic acid, 2-methylpentanedioic acid, 3-methylhexanedioic acid, etc. Suitable aromatic acids include terephthalic acid, isophthalic acid, phthalic acid, 4,4'-benzophenone dicarboxylic acid, 4,4'-diphenylmethanedicarboxylic acid, 4,4'-diphenylthioether dicarboxylic acid, and 4,4'-diphenylamine dicarboxylic acid. In some embodiments, the structure between the two carboxyl groups in the diacid contains only carbon and hydrogen atoms. In some specific embodiments, the structure between the two carboxyl groups in the diacid is a phenylene group. Blends of the aforementioned discretes may be used.

Diols include branched, unbranched, and cyclic aliphatic diols having 2 to 12 carbon atoms. Examples of suitable diols include ethylene glycol, 1,3-propylene glycol, 1,2-propylene glycol, 1,4-butanediol, 1,3-butanediol, 1,5-pentanediol, 2-methyl. -2,4-pentanediol, 1,6-hexanediol, cyclobutane-1,3-di(2′-ethanol), cyclohexane-1,4-dimethanol, 1,10-decanediol, 1,12-dodecanediol, and neopentyl glycol. Long chain diols can also be used, including poly(oxyalkylene)glycols in which the alkylene group contains 2 to 9 carbon atoms (e.g., 2 to 4 carbon atoms). Blends of the diols described above may be used.

Useful commercially available hydroxyl terminated polyester materials include various saturated linear semi-crystalline copolyesters available from Evonik Industries, Essen, North Rhine-Westphalia, Germany, such as DYNAPOL )™ S1401, Dynapol™ S1402, Dynapol™ S1358, Dynapol™ S1359, Dynapol™ S1227, and Dynapol™ S1229. Useful saturated linear amorphous copolyesters available from Evonik Industries include Dynapol™ 1313 and Dynapol™ S1430.

The curable composition may include one or more thermoplastic polyesters in varying amounts depending on the desired properties of the polishing layer. In some embodiments, the curable composition includes one or more thermoplastic polyesters in an amount of up to 50 weight percent based on the total weight of monomers/copolymers in the curable composition. If present, the one or more thermoplastic polyesters, in some embodiments, are present in an amount of at least 5%, at least 10%, at least 12%, at least 15%, or 20% by weight, based on the total weight of monomers/copolymers in the composition. It is present in an amount of more than % by weight. If present, the one or more thermoplastic polyesters, in some embodiments, are present in an amount of no more than 20%, no more than 25%, no more than 30%, no more than 40% by weight, based on the total weight of monomers/copolymers in the curable composition. It is present in an amount of 50% by weight or less.

In some embodiments, the curable composition includes one or more epoxy resins, which are polymers that include at least one epoxide functional group. The epoxy resin or epoxide useful in the compositions of the present invention can be any organic compound having at least one oxirane ring polymerizable by ring opening. In some instances, the average epoxy functional group in the epoxy resin is greater than 1, and in some cases, 2 or more. The epoxide may be a monomeric or polymeric epoxide, and may be an aliphatic, cycloaliphatic, heterocyclic, aromatic, hydrogenated epoxide, or mixtures thereof. In some examples, the epoxide contains more than 1.5 epoxy groups per molecule, and in some cases more than 2 epoxy groups per molecule. Useful materials typically have a weight average molecular weight of 150 g/mol to 10,000 g/mol (eg, 180 g/mol to 1,000 g/mol). The molecular weight of the epoxy resin can be selected to provide the desired properties of the curable or cured composition. Suitable epoxy resins include linear polymer epoxides with terminal epoxy groups (e.g., diglycidyl ethers of polyoxyalkylene glycols), polymer epoxides with skeletal epoxy groups (e.g., polybutadiene poly epoxy), and Polymeric epoxides with pendant epoxy groups (e.g., glycidyl methacrylate polymers or copolymers), and mixtures thereof. Epoxide-containing materials include compounds having the general formula:

Here, R ¹ is alkyl, alkoxy, or aryl, and n is an integer from 1 to 6.

Epoxy resins include aromatic glycidyl ethers, such as those prepared by reacting, for example, polyhydric phenols with an excess of epichlorohydrin, cycloaliphatic glycidyl ethers, hydrogenated glycidyl ethers, and mixtures thereof. do. Such polyhydric phenols include resorcinol, catechol, hydroquinone, and polynuclear phenols such as p,p'-dihydroxydibenzyl, p,p'-dihydroxydiphenyl, p,p'- Dihydroxyphenyl sulfone, p,p'-dihydroxybenzophenone, 2,2'-dihydroxy-1,1-dinaphthylmethane, and dihydroxydiphenylmethane, dihydroxydiphenyldimethyl. Methane, dihydroxydiphenylethylmethylmethane, dihydroxydiphenylmethylpropylmethane, dihydroxydiphenylethylphenylmethane, dihydroxydiphenylpropylphenylmethane, dihydroxydiphenylbutylphenylmethane, dihydroxy 2,2', 2,3', 2,4', 3 of diphenyltolylethane, dihydroxydiphenyltolylmethylmethane, dihydroxydiphenyldicyclohexylmethane, and dihydroxydiphenylcyclohexane; May include 3', 3,4', and 4,4' isomers.

Polyglycidyl ethers containing only epoxy or hydroxy groups as reactive groups are also useful, as well as polyphenolic formaldehyde condensation products. Useful curable epoxy resins are described, for example, in Lee and Nevil, Handbook of Epoxy Resins (McGraw-Hill Book Co. 1967), and Encyclopedia of Polymer Science and Technology, 6, p.322 (1986). It has also been described in various publications, including .

The choice of epoxy resin used may depend on its intended end use. For example, if a greater amount of ductility is desired, an epoxide with a “flexible backbone” may be desired. Materials such as diglycidyl ether of bisphenol A and diglycidyl ether of bisphenol F can provide the desirable structural properties that these materials acquire upon curing, while hydrogenated versions of these epoxies are oily. It can be useful for compatibility with substrates having a surface.

Examples of commercially available epoxides useful in the present invention include diglycidyl ether of bisphenol A (e.g., EPON trade name from Momentive Specialty Chemicals, Inc., Waterford, NY); (EPON)™ 828, EPON™ 1001, EPON™ 1004, EPON™ 2004, EPON™ 1510, and EPON™ 1310; available under the trademark D.E.R.™ from Dow Chemical Co., Midland, MI. 331, D.E.R.™ 332, D.E.R.™ 334, and D.E.N.™ 439; and those available from Hexion under the trade names EPONEX™ 1510); diglycidyl ether of bisphenol F (e.g., available under the trade name ARALDITE™ GY 281 from Huntsman Corporation); Silicone resin containing diglycidyl epoxy functional group; flame retardant epoxy resins (e.g., a brominated bisphenol type epoxy resin available under the trade designation D.E.R.™ 560, available from The Dow Chemical Company); and 1,4-butanediol diglycidyl ether.

An epoxy-containing compound having at least one glycidyl ether terminus and, in some cases, a saturated or unsaturated cyclic backbone may optionally be added to the curable composition as a reactive diluent. Reactive diluents are used for a variety of purposes, for example, to aid in processing, for example, to control viscosity in the curable composition, as well as to make the cured composition more flexible upon curing, or to make the composition more flexible. It can be added to commercialize the ingredients within.

Examples of such diluents include diglycidyl ether of cyclohexanedimethanol, diglycidyl ether of resorcinol, p-tert-butyl phenyl glycidyl ether, cresyl glycidyl ether, and diglycidyl ether of neopentyl glycol. Glycidyl ether, triglycidyl ether of trimethylolethane, triglycidyl ether of trimethylolpropane, triglycidyl p-amino phenol, N,N'-diglycidylaniline, N,N , N'N'-tetraglycidyl meta-xylylene diamine, and vegetable oil polyglycidyl ether. Reactive diluents are commercially available from Momentive Specialty Chemicals, Inc. as HELOXY™ 107 and CARDURA™ N10. The composition may contain toughening agents to help provide peel resistance, and impact strength, among other properties.

The curable composition may contain one or more epoxy resins having an epoxy equivalent weight of 100 g/mol to 1500 g/mol. In some examples, the curable composition contains one or more epoxy resins having an epoxy equivalent weight of 300 g/mol to 1200 g/mol. And in other embodiments, the curable compositions of various embodiments described herein contain two or more epoxy resins, wherein at least one epoxy resin has an epoxy equivalent weight of 300 g/mol to 500 g/mol, and at least one epoxy resin has an epoxy equivalent weight of 1000 g/mol to 1200 g/mol.

The curable composition may include one or more epoxy resins in amounts that vary depending on the desired properties of the curable composition that make up the abrasive layer of the abrasive articles of the various embodiments described herein. In some embodiments, the curable composition comprises one or more compounds in an amount of at least 20 parts by weight, at least 25 parts by weight, at least 35 parts by weight, at least 40 parts by weight, at least 50 parts by weight, or at least 55 parts by weight, based on 100 parts by weight of the total weight of the composition. Contains epoxy resin. In some embodiments, the one or more epoxy resins are present in an amount of no more than 45, no more than 50, no more than 75, or no more than 80 parts by weight, based on 100 parts by total weight of monomers/copolymers in the curable composition.

Vinyl ethers represent another class of monomers that, like epoxy resins, are cationically polymerizable. These monomers can be used as alternatives to, or in combination with, the epoxy resins disclosed herein.

Without wishing to be bound by any particular theory, it is believed that vinyl ether monomers have high electron density in the double bond and generate stable carbocations, which may render these monomers highly reactive in cationic polymerizations. . To avoid inhibition of cationic polymerization, vinyl ether monomers may be limited to those that do not contain nitrogen. Examples include methyl vinyl ether, ethyl vinyl ether, tert-butyl vinyl ether, isobutyl vinyl ether, triethylene glycol divinyl ether, and 1,4-cyclohexane dimethanol divinyl ether. Preferred examples of vinyl ether monomers include triethylene glycol divinyl ether and cyclohexane dimethanol divinyl ether (both sold under the trademark RAPI by Ashland, Inc., Covington, KY). -CURE) is included.

The curable composition may further include one or more hydroxy-functional polyethers. In some embodiments, the one or more hydroxy-functional polyethers are liquid at a temperature of 25° C. and a pressure of 1 atm (101 kilopascals). In some embodiments, the one or more hydroxy-functional polyethers include polyether polyols. The polyether polyol may be present in an amount of at least 5 parts, at least 10 parts, or up to 15 parts per 100 parts by total weight of monomers/copolymers in the composition. In some embodiments, the polyether polyol is present in an amount of no more than 15 parts, no more than 20 parts, or no more than 30 parts per 100 parts by total weight of monomers/copolymers in the composition.

Examples of hydroxy-functional polyethers include polyoxyethylene and polyoxypropylene glycol; Includes, but is not limited to, polyoxyethylene and polyoxypropylene triol and polytetramethylene oxide glycol.

Suitable hydroxy-functional poly(alkyleneoxy) compounds include polytetramethylene oxide glycols of the POLYMEG™ series (from Lyondellbasell, Inc., Jackson, TN); polytetramethylene oxide glycol of the TERATHANE™ series (from Invista, Newark, DE); polytetramethylene oxide glycol of the POLYTHF™ series (from BASF SE, Ludwigshafen, Germany); Polyoxypropylene polyols of the ARCOL™ series (from Bayer MaterialScience LLC, Pittsburgh, PA, USA) and Boranol (from The Dow Chemical Company, Midland, MI, USA) Includes, but is not limited to, the (VORANOL)™ series of polyether polyols.

The curable compositions of various embodiments described herein, used to form an abrasive layer, may further contain at least one polyhydroxyl-functional compound having at least one, and in some cases at least two, hydroxyl groups. You can. As used herein, the term “polyhydroxyl-functional compound” does not include the polyether polyols described herein that also contain hydroxyl groups. In some embodiments, the polyhydroxyl-functional compound is substantially free of other “active hydrogen” containing groups, such as amino and mercapto moieties. Additionally, the polyhydroxyl-functional compounds are also substantially free of groups that may be thermally and/or photolytically unstable so that the compounds will not decompose when exposed to UV radiation and, in some cases, heat during curing.

Polyhydroxyl-functional compounds, in some cases, contain two or more primary or secondary aliphatic hydroxyl groups (i.e., the hydroxyl groups are directly bonded to non-aromatic carbon atoms). In some embodiments, the polyhydroxyl-functional compound has a hydroxyl number of 0.01 or greater. Without wishing to be bound by any particular theory, it is believed that the hydroxyl groups participate in cationic polymerization with the epoxy resin.

The polyhydroxyl-functional compound may be selected from phenoxy resins, ethylene-vinyl acetate (“EVA”) copolymers, polycaprolactone polyols, polyester polyols, and polyvinyl acetal resins that are solid under ambient conditions. In some embodiments, the polyhydroxyl-functional compound is solid at a temperature of 25° C. and a pressure of 1 atm (101 kilopascals). The hydroxyl groups may be located terminally or may be pendant from the polymer or copolymer. In some embodiments, adding a polyhydroxyl-functional compound to the curable compositions of various embodiments described herein improves the dynamic lap shear strength and/or slows cold flow of the curable composition used to prepare the abrasive layer. can be reduced.

One useful class of polyhydroxyl-functional compounds are hydroxy-containing phenoxy resins. Preferred phenoxy resins include those derived from the polymerization of diglycidyl bisphenol compounds. Typically, the phenoxy resin has a number average molecular weight of less than 60,000 g/mol (eg, in the range of 20,000 g/mol to 30,000 g/mol). Commercially available phenoxy resins include PAPHEN™ PKHP-200 available from Inchem Corp., Rock Hill, SC and Milliken Chemical, Spartanburg, SC. SYN FAC™ series of polyoxyalkylated bisphenol A, such as SYN FAC™ 8009, 8024, 8027, 8026, and 8031.

Another useful class of polyhydroxyl-functional compounds are those of EVA copolymer resins. Without wishing to be bound by any particular theory, it is believed that these resins contain small amounts of free hydroxyl groups and that the EVA copolymers are further deacetylated during cationic polymerization. Hydroxyl-containing EVA resins can be obtained, for example, by partially hydrolyzing the precursor EVA copolymer.

Suitable ethylene-vinyl acetate copolymer resins include, but are not limited to, thermoplastic EVA copolymer resins containing at least 28 weight percent vinyl acetate. In one embodiment, the EVA copolymer has at least 28% vinyl acetate by weight, preferably at least 40% vinyl acetate (e.g., at least 50% vinyl acetate and at least 60% vinyl acetate by weight), based on the weight of the copolymer. ), including thermoplastic copolymers containing. In a further embodiment, the EVA copolymer has 28 to 99 weight percent vinyl acetate (e.g., 40 to 90 weight percent vinyl acetate; 50 to 90 weight percent vinyl acetate; and 60 to 80 weight percent vinyl acetate) in the copolymer. Contains an amount of vinyl acetate in the range of vinyl acetate).

Examples of commercially available EVA copolymers include EVA, Wilmington, Delaware, USA. kid. ELVAX™ series including ELVAX™ 150, 210, 250, 260, and 265 from E. I. Du Pont de Nemours and Co., Celanese, Irving, TX. ATEVA™ series from Celanese, Inc.; LEVAPREN™ 400 (45 wt% vinyl acetate) from Bayer Corp., Pittsburgh, PA, including LEVAPREN™ 450, 452, and 456; Levaprene™ 500 HV (50% vinyl acetate by weight); Levaprene™ 600 HV (60% vinyl acetate by weight); Levaprene™ 700 HV (70% vinyl acetate by weight); and Levaprene™ KA 8479 (80 wt% vinyl acetate), each from Lanxess Corp., Cologne, Germany.

Additional useful polyhydroxyl-functional compounds include the TONE™ series of polycaprolactone polyols available from Dow Chemical, and the Kappa of polycaprolactone polyols from Perstorp Inc., Perstorp, Sweden. (CAPA)™ series, and the DESMOPHEN™ series of saturated polyester polyols from Bayer Corporation, Pittsburgh, Pa., such as DESMOPHEN™ 631A 75.

The curable composition, whether cured or uncured, includes at least one polyhydroxyl-functional compound in an amount that may vary depending on the desired properties of the curable composition. The curable composition comprises at least one polyhydroxyl-functional compound in an amount of at least 10 parts by weight, at least 15 parts by weight, at least 20 parts by weight, or at least 25 parts by weight based on 100 parts by total weight of monomers/copolymers in the composition. can do. In some embodiments, the at least one polyhydroxyl-functional compound can be present in an amount of up to 20 parts, up to 25 parts, or up to 50 parts based on 100 parts by total weight of monomers/copolymers in the composition.

Photoinitiators useful for use in the curable compositions of various embodiments described herein include i) a photoinitiator used to polymerize the precursor polymer (e.g., in some embodiments, a tetrahydrofurfuryl (meth)acrylate copolymer) and ii) those used to ultimately polymerize the curable composition.

Photoinitiators for the former include benzoin ethers, such as benzoin methyl ether and benzoin isopropyl ether; Substituted acetophenones, such as IRGACURE™ 651 (BASF SE) or ESACURE™ KB-1 (Sartomer Co., West Chester, PA) Possible 2,2-dimethoxy-1,2-diphenylethanone, dimethoxyhydroxyacetophenone; substituted α-ketols such as 2-methyl-2-hydroxy propiophenone; aromatic sulfonyl chlorides, such as 2-naphthalene-sulfonyl chloride; and photoactive oximes, such as 1-phenyl-1,2-propanedione-2-(O-ethoxy-carbonyl)oxime. In some specific embodiments, the photoinitiator is a substituted acetophenone.

In some embodiments, the photoinitiator is a photoactive compound that generates free radicals via Norrish I cleavage, which may be initiated by an addition reaction to an acrylic double bond. In some embodiments, such photoinitiator is present in an amount of 0.1 to 1.0 pbw per 100 parts of precursor polymer composition. Examples of such photoinitiators include, but are not limited to, ionic photoacid generators, which are compounds that can generate acids upon exposure to actinic radiation. They are widely used to initiate cationic polymerizations, in which case they are referred to as cationic photoinitiators.

Useful ionic photoacid generators include bis(4-t-butylphenyl)iodonium hexafluoroantimonate (FP5034™ from Hamford Research Inc., Stratford, CT, USA); A mixture of triarylsulfonium salts (diphenyl(4-phenylthio) phenylsulfonium hexafluoroantimonate, available as Syna PI-6976™ from Synasia, Metuchen, NJ). Bis(4-(diphenylsulfonio)phenyl)sulfide hexafluoroantimonate), (4-methoxyphenyl)phenyl iodonium triflate, bis(4-fert-butylphenyl)iodonium camphor Sulfonate, bis(4-tert-butylphenyl)iodonium hexafluoroantimonate, bis(4-tert-butylphenyl)iodonium hexafluorophosphate, bis(4-tert-butylphenyl)iodo Nitrium tetraphenylborate, bis(4-tert-butylphenyl)iodonium tosylate, bis(4-tert-butylphenyl)iodonium triflate, ([4-(octyloxy)phenyl]phenyliodonium hexahydrate fluorophosphate), ([4-(octyloxy)phenyl]phenyliodonium hexafluoroantimonate), (4-isopropylphenyl)(4-methylphenyl)iodonium tetrakis(pentafluorophenyl) Borate (available as Rhodorsil 2074™ from Bluestar Silicones, East Brunswick, NJ), bis(4-methylphenyl)iodonium hexafluorophosphate (Bartle, IL) 4-(2-hydroxy-1-tetradecyloxy)phenyl]phenyl iodonium hexafluoroantimo, available as Omnicat 440™ from IGM Resins, Lit. nate, triphenyl sulfonium hexafluoroantimonate (available as CT-548™ from Chitec Technology Corp., Taipei, Taiwan), diphenyl(4-phenylthio)phenylsulfonium hexafluoro Phosphate, bis(4-(diphenylsulfonio)phenyl)sulfide bis(hexafluorophosphate), diphenyl(4-phenylthio)phenylsulfonium hexafluoroantimonate, bis(4-(diphenylsulfonate) fonio)phenyl)sulfide hexafluoroantimonate, and these triarylsulfoniums available from Cinacia, Metuchen, NJ, as Cina™ PI-6992 and Cina™ PI-6976 for the PF6 and SbF6 salts, respectively. Blends of salts are included. Similar blends of ionic photoacid generators are available as UVI-6992 and UVI-6976 from Aceto Pharma Corporation, Port Washington, NY.

The photoinitiator is used in an amount sufficient to achieve the desired degree of crosslinking of the copolymer. The desired degree of crosslinking may depend on the desired properties of the abrasive layer (whether cured or uncured) or the thickness of the abrasive layer (whether cured or uncured). The amount of photoinitiator required to achieve the desired degree of crosslinking will depend on the quantum yield of the photoinitiator (number of molecules of acid released per photon absorbed), the transmittance of the polymer matrix, the wavelength and duration of irradiation, and the temperature. Typically, the photoinitiator is used in an amount of at least 0.001 part by weight, at least 0.005 part by weight, at least 0.01 part by weight, at least 0.05 part by weight, at least 0.1 part by weight, or at least 0.5 part by weight, based on 100 parts by weight of total monomer/copolymer in the composition. . The photoinitiator is generally used in an amount of up to 5 parts by weight, up to 3 parts by weight, up to 1 part by weight, up to 0.5 part by weight, up to 0.3 part by weight, or up to 0.1 part by weight, based on 100 parts by weight of total monomer/copolymer in the composition. do.

The curable compositions of various embodiments described herein may further contain any number of optional additives. Such additives may be homogeneous or heterogeneous with one or more components in the composition. Heterogeneous additives may be discrete (eg, particulate) or substantially continuous.

The above-described additives include compositions used in the provided method to reduce the weight and/or cost of the structural layer composition, adjust the viscosity, and/or provide additional reinforcement or allow faster or more uniform curing to be achieved. and to modify the thermal conductivity of the article, such as fillers, stabilizers, plasticizers, tackifiers, flow control agents, cure rate retarders, adhesion promoters (e.g., (3-glycidoxypropyl )Silanes such as trimethoxysilane (GPTMS), and titanates), adjuvants, impact modifiers, expandable microspheres, thermally conductive particles, electrically conductive particles, etc., such as silica, glass, clay, talc, Pigments, colorants, glass beads or bubbles, and antioxidants may be included.

In some embodiments, the curable composition may contain one or more fiber reinforcement materials. The use of fiber reinforced materials can provide an abrasive layer with improved cold flow properties, limited stretchability, and improved strength. Preferably, the one or more fiber reinforced materials have a certain degree of porosity that allows photoinitiators to be dispersed throughout them to be activated by UV light and to cure properly without the need for heat.

The one or more fiber reinforcements may include, but are not limited to, woven fabrics, non-woven fabrics, knitted fabrics, and one or more fiber-containing webs including a unidirectional array of fibers. One or more fiber reinforcements may include non-woven fabric such as scrim.

The material for making one or more fiber reinforcements may include any fiber-forming material that can be formed into one of the webs described above. Suitable fiber-forming materials include polymeric materials such as polyesters, polyolefins, and aramids; organic materials such as wood pulp and cotton; inorganic materials such as glass, carbon, and ceramics; a coated fiber having a core component (e.g., any of the above fibers) and a coating thereon; and combinations thereof, but are not limited thereto.

Additional options and advantages of fiber reinforced materials are described in US Patent Application Publication No. 2002/0182955 (Weglewski et al.).

In some examples, the curable compositions of various embodiments described herein do not require heat for curing, although heat may be used to accelerate the curing process. Additionally, in some embodiments, the curable composition is prepared using a high temperature melt process that does not require volatile solvents because solvents are often undesirable due to costs associated with procurement, handling, and disposal.

As discussed herein, the polymerizable composition used to form the THFA copolymer component, the curable composition used to form the polishing layer, and/or the composition used to prepare the size coat may include one or more components ( s) can be irradiated using various activating UV light sources to polymerize (e.g., photopolymerize).

Light sources based on light emitting diodes can enable a number of advantages. These light sources may be monochromatic, meaning that for the purposes of the present invention the spectral power distribution is characterized by a very narrow wavelength distribution (eg limited to within the 50 nm range or less). Monochromatic ultraviolet light can reduce thermal damage or harmful deep UV effects on irradiated coatings and substrates. In larger scale applications, the lower power consumption of UV-LED sources can also enable energy savings and reduced environmental impact.

In some embodiments, matching the spectral distribution of the photoinitiator more closely to the absorption spectrum of the UV light source may result in poor curing of the thick abrasive layer. Without wishing to be bound by any particular theory, aligning the peak output of a UV source with the excitation wavelength of the photoinitiator dramatically increases the viscosity of the monomer mixture and gradually reduces the ability of the available monomers to access the reactive polymer chain ends. It is believed that this may be undesirable because it leads to the formation of an obstructive “skin” layer. The result of this lack of accessibility is that the abrasive layer beneath the skin layer becomes an uncured or only partially cured layer, and the abrasive layer subsequently fails to retain, for example, abrasive particles.

These technical problems can be alleviated by using a UV light source with a spectral distribution offset from the main excitation wavelength at which the photoinitiator is activated. As used herein, “offset” between a spectral distribution and a given wavelength means that the given wavelength does not overlap with a wavelength at which the output of a UV light source has significant intensity. In one embodiment, the above-mentioned offset is a positive offset (e.g., the spectral distribution spans a wavelength higher than the main excitation wavelength of the photoinitiator).

In the present invention, the main excitation wavelength is the highest wavelength absorption peak of the UV absorption curve of the photoinitiator (e.g., the local absorption maximum located at the highest wavelength), as determined by spectroscopic measurements at a photoinitiator concentration of 0.03% by weight in acetonitrile solution. peak) can be defined.

In some embodiments, the highest wavelength absorption peak is located at a wavelength of 395 nm or less, 375 nm or less, or 360 nm or less.

In some embodiments, the wavelength difference between the highest wavelength absorption peak of the photoinitiator and the peak intensity of the UV light source ranges from 30 nm to 110 nm, preferably from 40 nm to 90 nm, and more preferably from 60 nm to 80 nm. .

The UV radiation exposure time required to obtain sufficient activation of the photoinitiator(s) is not particularly limited. In some embodiments, the curable composition is exposed to ultraviolet radiation over an exposure period of at least 0.25 seconds, at least 0.35 seconds, at least 0.5 seconds, or at least 1 second. The curable composition may be exposed to ultraviolet radiation over an exposure period of 10 minutes or less, 5 minutes or less, 2 minutes or less, 1 minute or less, or 20 seconds or less.

Based on the exposure time used, UV radiation should provide sufficient energy density to achieve a functional cure. In some embodiments, UV radiation can deliver an energy density of at least 0.5 J/cm2, at least 0.75 J/cm2, or at least 1 J/cm2. In the same or alternative embodiments, the UV radiation may deliver an energy density of less than or equal to 15 J/cm2, less than or equal to 12 J/cm2, or less than or equal to 10 J/cm2.

A wide variety of abrasive particles may be used in the various embodiments described herein. Suitable abrasive particles include, for example, alumina, brown aluminum oxide, blue aluminum oxide, silicon carbide (including green silicon carbide), titanium diboride, boron carbide, tungsten carbide, garnet, titanium carbide, diamond, cubic. boron nitride, garnet, fused alumina zirconia, iron oxide, chromia, zirconia, titania, tin oxide, quartz, feldspar, flint, emery, sol-gel-derived ceramics (e.g. alpha alumina), and It could be a combination of these.

Abrasive particles may be available in a variety of sizes, shapes, and profiles, including, for example, random or broken shapes, regular (e.g., symmetric) profiles, such as square, star-shaped, or hexagonal profiles, and irregular (e.g., asymmetric) profiles. You can.

An abrasive article may include a mixture of different types of abrasive particles. For example, the abrasive article may be a mixture of planar and non-planar particles, a mixture of crushed and shaped particles (which may be individual abrasive particles without a binder or may be agglomerated abrasive particles containing a binder), mixtures of conventional unshaped abrasive particles and non-shaped abrasive particles (e.g., filler materials), and mixtures of abrasive particles of different sizes.

Examples of suitable shaped abrasive particles can be found, for example, in US Pat. Nos. 5,201,916 (Berg) and 8,142,531 (Adefris et al.). Materials that can form shaped abrasive particles include alpha alumina. Shaped abrasive particles of alpha alumina can be prepared from a dispersion of aluminum oxide monohydrate that is gelled, shaped into a given shape, dried, calcined and sintered to maintain that shape according to techniques known in the art.

U.S. Patent No. 8,034,137 (Erickson et al.) describes alumina crushed abrasive particles that are formed into a specific shape and then crushed to form shards that retain some of their original shape features. In some embodiments, the shaped alpha alumina particles are precisely shaped (i.e., the particles have a shape determined at least in part by the shape of the cavities in the production tool used to manufacture the particles). Details regarding such shaped abrasive particles and methods of making them can be found, for example, in U.S. Pat. No. 8,142,531 (Adepris et al.); No. 8,142,891 (Culler, etc.); and 8,142,532 (Ericson et al.); US Patent Application Publication No. 2012/0227333 (Adepris et al.); No. 2013/0040537 (Schwabel et al.); and 2013/0125477 (Adefris).

Examples of suitable crushed abrasive particles include fused aluminum oxide, heat-treated aluminum oxide, white fused aluminum oxide, and 3M CERAMIC ABRASIVE grains available from 3M Company, St. Paul, MN. Ceramic aluminum oxide materials such as those available as GRAIN, brown aluminum oxide, blue aluminum oxide, silicon carbide (including green silicon carbide), titanium diboride, boron carbide, tungsten carbide, garnet, titanium carbide, diamond, cubic Boron nitride, garnet, fused alumina zirconia, iron oxide, chromia, zirconia, titania, tin oxide, quartz, feldspar, flint, emery, sol-gel-derived ceramics (e.g. alpha alumina), and combinations thereof. . Additional examples include crushed abrasive composites of abrasive particles (which may or may not be plate-shaped) in a binder matrix, such as those described in U.S. Pat. No. 5,152,917 (Pieper et al.).

Examples of sol-gel-derived abrasive particles and methods for making the same, from which crushed abrasive particles can be isolated, include U.S. Pat. No. 4,314,827 (Leitheiser et al.); No. 4,623,364 (Cottringer et al.); Nos. 4,744,802 (Schwabel), 4,770,671 (Monroe et al.); and No. 4,881,951 (Monro et al.). It is also contemplated that the broken abrasive particles may comprise abrasive agglomerates such as those described, for example, in U.S. Pat. No. 4,652,275 (Bloecher et al.) or 4,799,939 (Bloecher et al.).

Fractured abrasive particles include, for example, ceramic crushed abrasive particles, such as sol-gel-derived polycrystalline alpha alumina particles. Ceramic crushed abrasive particles composed of crystallites of alpha alumina, magnesium alumina spinel, and rare earth hexagonal aluminates are described, for example, in U.S. Pat. No. 5,213,591 (Celikkaya et al.) and U.S. Patent Application Publication No. 2009. It can be prepared using sol-gel precursor alpha alumina particles according to the method described in /0165394 A1 (Cooler et al.) and 2009/0169816 A1 (Ericson et al.).

Additional details regarding methods of making sol-gel-derived abrasive particles can be found, for example, in U.S. Pat. No. 4,314,827 (Ratizer); No. 5,152,917 (Pipper et al.); No. 5,435,816 (Spurgeon et al.); Nos. 5,672,097 (Hoopman et al.), 5,946,991 (Hoopman et al.), 5,975,987 (Hoopman et al.), and 6,129,540 (Hoopman et al.), and US Patent Application Publication No. 2009/0165394 Al It can be found in arcs (coolers, etc.). Examples of suitable crushed plate-shaped abrasive particles can be found, for example, in US Pat. No. 4,848,041 (Kruschke).

The abrasive particles may be surface-treated with a coupling agent (eg, an organosilane coupling agent) or other physical treatment agent (eg, iron oxide or titanium oxide) to improve the adhesion of the broken abrasive particles to the binder.

In some embodiments, the abrasive layer includes a plurality of shaped abrasive particles (e.g., precision shaped grain (PSG) mineral particles available from 3M, St. Paul, MN, as described in more detail herein; 1, not shown in FIGS. 3A, 3B, 4A or 4B) and a particulate mixture comprising a plurality of abrasive particles 106, or only molded abrasive particles adhesively fixed to the abrasive layer.

As used herein, the term “shaped abrasive particle” generally refers to an abrasive particle having an at least partially replicated shape (e.g., a shaped ceramic abrasive particle). Non-limiting processes for making shaped abrasive particles include shaping the precursor abrasive particles in a mold with a predetermined shape, extruding the precursor abrasive particles through an orifice with a predetermined shape, or printing screens with a predetermined shape. and printing precursor abrasive particles through openings in the abrasive particles, or embossing the precursor abrasive particles into a predetermined shape or pattern. Non-limiting examples of shaped abrasive particles are disclosed in US Patent Application Publication No. 2013/0344786, which is incorporated by reference as if fully set forth herein. Non-limiting examples of shaped abrasive particles include US Patent RE 35,570; Shaped abrasive particles formed within a mold, e.g., a triangular plate, as disclosed in US Pat. Nos. 5,201,916 and 5,984,998, all of which are incorporated by reference as if fully set forth herein; or extruded long ceramic rods/filaments, often of circular cross-section, produced by Saint-Gobain Abrasives, examples of which are incorporated by reference as if fully set forth herein. disclosed in Patent No. 5,372,620). As used herein, shaped abrasive particles exclude randomly sized abrasive particles obtained by mechanical crushing operations.

Shaped abrasive particles also include shaped abrasive particles. As used herein, the term “shaped abrasive particle” generally refers to an abrasive particle having a predetermined shape, at least a portion of which is replicated from a mold cavity used to form the shaped precursor abrasive particle. do. Except in the case of abrasive shards (e.g., as described in U.S. Patent Application Publication No. 2009/0169816), shaped abrasive particles generally substantially replicate the mold cavity that was used to form the shaped abrasive particles. It will have a predetermined geometric shape. As used herein, shaped abrasive particles exclude randomly sized abrasive particles obtained by mechanical crushing operations.

Shaped abrasive particles also include “plate-shaped crushed abrasive particles” such as those described in International Patent Publication No. WO2016/160357, which is incorporated by reference as if fully described herein. Briefly, the term “platelet-shaped broken abrasive particles” refers to broken abrasive particles that resemble platelets and/or flakes, generally characterized by a thickness that is less than their width and length. For example, the thickness may be less than 1/2, 1/3, 1/4, 1/5, 1/6, 1/7, 1/8, 1/9, or even 1/9 of the length and/or width. It can be less than 10. Likewise, the width can be less than 1/2, 1/3, 1/4, 1/5, 1/6, 1/7, 1/8, 1/9, or even less than 1/10 of the length.

Shaped abrasive particles also include fine shaped grain (PSG) mineral particles, such as those described in US Patent Application Publication No. 2015/267097, which is incorporated by reference as if fully set forth herein.

The molded abrasive particles and abrasive particles may be made from the same or different materials. For example, the shaped abrasive particles and abrasive particles 106 are not limited and may be composed of any of a variety of hard minerals known in the art. Examples of suitable abrasive particles include, for example, fused aluminum oxide, heat treated aluminum oxide, white fused aluminum oxide, black silicon carbide, green silicon carbide, titanium diboride, boron carbide, silicon nitride, tungsten carbide, carbide. Titanium, diamond, cubic boron nitride, hexagonal boron nitride, garnet, fused alumina zirconia, alumina-based sol gel-derived abrasive particles, silica, iron oxide, chromia, ceria, zirconia, titania, tin oxide, gamma alumina, and these. includes mixtures of Alumina abrasive particles may contain metal oxide modifiers. Diamond and cubic boron nitride abrasive particles can be single crystalline or polycrystalline.

Molded abrasive particles can be prepared according to methods known in the art, including those described in US Patent Application Publication No. 2015/267097, which is incorporated by reference as if fully described herein.

In some examples, the shaped abrasive particles have a size of about 80 micrometers to about 150 micrometers (e.g., about 75 micrometers to about 150 micrometers; about 90 micrometers to about 110 micrometers; about 90 micrometers to about 100 micrometers) micrometers; about 85 micrometers to about 110 micrometers; or about 95 micrometers to about 120 micrometers). As used herein, the term “substantially monodisperse particle size” is used to describe shaped abrasive particles having a substantially unchanging size. Thus, for example, when referring to shaped abrasive particles (e.g., PSG mineral particles) with a particle size of 100 micrometers, more than 90%, more than 95%, or more than 99% of the shaped abrasive particles have the maximum dimension. We will have particles that are 100 micrometers.

In contrast, abrasive particles 106 may have a range or distribution of particle sizes. Such distribution can be characterized by its median particle size. For example, the median particle size of the abrasive particles may be at least 0.01 micrometers, at least 0.10 micrometers, at least 0.50 micrometers, at least 5 micrometers, at least 10 micrometers, or even at least 20 micrometers. In some cases, the median particle size of the abrasive particles may be 1000 micrometers or less, 800 micrometers or less, 600 micrometers or less, 400 micrometers or less, 300 micrometers or less, 250 micrometers or less, 150 micrometers or less, or even It may be less than 100 micrometers. In some examples, the median particle size of the abrasive particles is from about 10 micrometers to about 800 micrometers, from about 20 micrometers to about 800 micrometers, from about 40 micrometers to about 800 micrometers, from about 10 micrometers to about 600 micrometers. and from about 20 micrometers to about 600 micrometers, from about 40 micrometers to about 600 micrometers, from about 10 micrometers to about 400 micrometers, from about 20 micrometers to about 400 micrometers, or even from about 40 micrometers to about 40 micrometers. It is 800 micrometers.

In some embodiments, the molded abrasive particles and the abrasive particles are present in the particulate mixture included in the abrasive layer in different weight percent (% by weight) amounts relative to each other based on the total weight of the particulate mixture. In some examples, the particulate mixture includes from about 1% to less than 99% shaped abrasive particles, from about 2% to less than 50% shaped abrasive particles, and from about 3% to less than 20% shaped abrasives by weight. Contains particles. .

In some embodiments, the abrasive articles of various embodiments described herein include a size coat 202. In some examples, the size coat is a bis-epoxide (e.g., 3,4-epoxy cyclohexylmethyl-3,4 available from Daicel Chemical Industries, Ltd., Tokyo, Japan) -epoxy cyclohexylcarboxylate); trifunctional acrylates (e.g., trimethylol propane triacrylate, available under the trade designation “SR351” from Sartomer USA, LLC, Exton, Pa.); acidic polyester dispersants (e.g. “BYK W-985” from Byk-Chemie, GmbH, Wesel, Germany); fillers (e.g., sodium-potassium alumina silicate filler, available under the trade designation “MINEX 10” from The Cary Company, Addison, IL); Photoinitiators (e.g., triarylsulfonium hexafluoroantimonate/propylene carbonate photoinitiator, available under the trade designation “CYRACURE CPI 6976” from Dow Chemical Company, Midland, Mich.; and New Jersey, U.S.A. and cured (e.g., photopolymerized) products of α-hydroxyketone photoinitiators, available under the trade designation “DAROCUR 1173” from BASF Corporation, Florham Park, Inc.

The abrasive article of various embodiments described includes a supersize coat 204. Typically, the supersize coat is the outermost coating of the abrasive article and is in direct contact with the workpiece during the abrasive operation. The supersize coat is, in some instances, substantially transparent.

As used herein, the term “substantially transparent” refers to being majority or mostly transparent, such as at least about 30%, 40%, 50%, 60%, or at least about 70%. In some examples, a measure of the transparency of any given coat described herein (e.g., a supersize coat) is the transmittance of the coat. In some examples, the supersize coat transmits 500 nm light through a 6 x 12 inch x approximately 1 to 2 mil (15.24 x 30.48 cm x 25.4 to 50.8 μm) sample of transparent polyester film, with a transmission of about 98%. Depending on the transmittance test that measures the transmittance, a transmittance of at least 5%, at least 20%, at least 40%, at least 50%, or at least 60% (e.g., about 40% to about 80%; about 50% to about 70% ; about 40% to about 70%; or about 50% to about 70% transmittance).

One component of the supersize coat can be metal salts of long chain fatty acids (eg, C ₁₂ -C ₂₂ fatty acids, C ₁₄ -C ₁₈ fatty acids, and C ₁₆ -C ₂₀ fatty acids). In some examples, the metal salt of a long chain fatty acid is a stearate salt (eg, a salt of stearic acid). The conjugate base of stearic acid is C ₁₇ H ₃₅ COO-, also known as the stearate anion. Useful stearates include, but are not limited to, calcium stearate, zinc stearate, and combinations thereof.

The metal salt of the long chain fatty acid is present in an amount of at least 10%, at least 50%, at least 70%, at least 80% by weight, based on the normalized weight of the supersize coat (i.e., the average weight per unit surface area of the abrasive article). It may be present in an amount of 90% by weight or more. The metal salt of the long chain fatty acid is present in an amount of less than 100%, less than 99%, less than 98%, less than 97%, less than 95%, less than 90%, less than 80% by weight, based on the normalized weight of the supersize coat. , or up to 60% by weight (e.g., about 10% to about 100% by weight; about 30% to about 70% by weight; about 50% to about 90% by weight; or about 50% to about 100% by weight) It can exist in an amount of .

Another component of the supersize composition is a polymeric binder, which, in some instances, allows the composition used to form the supersize coat to form a smooth, continuous film over the abrasive layer. In one example, the polymeric binder is a styrene-acrylic polymeric binder. In some examples, the styrene-acrylic polymeric binder is an ammonium salt of a modified styrene-acrylic polymer such as, but not limited to, JONCRYL® LMV 7051. The ammonium salt of the styrene-acrylic polymer may, for example, have a weight average molecular weight (Mw) of at least 100,000 g/mol, at least 150,000 g/mol, at least 200,000 g/mol, or at least 250,000 g/mol (e.g., about 100,000 g/mol to about 2.5×10 ⁶ g/mol; about 100,000 g/mol to about 500,000 g/mol; or about 250,000 to about 2.5×10 ⁶ g/mol).

The minimum film-forming temperature, also referred to as MFFT, is the lowest temperature at which a polymer self-coalesce in a semi-dry state to form a continuous polymer film. In the context of the present invention, this polymer film can function as a binder for the remaining solids present in the supersize coat. In some examples, the styrene-acrylic polymeric binder (e.g., an ammonium salt of a styrene-acrylic polymer) has a MFFT of 90°C or less, 80°C or less, 70°C or less, 65°C or less, or 60°C or less.

In some examples, the binder is dried at relatively low temperatures (e.g., below 70° C.). In some examples, the drying temperature is below the melting temperature of the metal salt component of the long chain fatty acid component of the supersize coat. It is undesirable to use excessively high temperatures (e.g., temperatures above 80°C) to dry supersize coats because they cause embrittlement and cracking in the backing, complicate web handling, and may cause manufacturing problems. This is because it can increase costs. Thanks to its low MFFT, for example binders consisting of ammonium salts of styrene-acrylic polymers, supersize coats can be used with lower binders without the need for added surfactants such as DOWANOL® DPnP. It makes it possible to achieve better film formation at higher and lower temperatures.

The polymeric binder may be present in an amount of at least 0.1 weight percent, at least 1 weight percent, or at least 3 weight percent based on the normalized weight of the supersize coat. The polymeric binder may be present in an amount of up to 20%, up to 12%, up to 10%, or up to 8% by weight, based on the normalized weight of the supersize coat. Advantageously, when ammonium salts of modified styrene acrylic copolymers are used as binders, the haze normally associated with stearate coatings is substantially reduced.

The supersize coat of the present invention optionally contains clay particles dispersed in the supersize coat. If present, the clay particles can be uniformly mixed with the metal salts of long-chain fatty acids, polymeric binder, and other components of the supersize composition. Clays can impart unique advantageous properties to abrasive articles, such as improved optical clarity and improved cutting performance. The inclusion of clay particles can also allow cutting performance to be sustained for a longer period of time compared to supersize coats without clay additives.

The clay particles, if present, may be present in an amount of at least 0.01%, at least 0.05%, at least 0.1%, at least 0.15%, or at least 0.2% by weight, based on the normalized weight of the supersize coat. Additionally, the clay particles may be present in an amount of less than 99%, less than 50%, less than 25%, less than 10%, or less than 5% by weight, based on the normalized weight of the supersize coat.

Clay particles may include particles of any known clay material. Such clay materials include smectite, kaolin, illite, chlorite, serpentine, attapulgite, palygorskite, vermiculite, and glauconite. ), sepiolite, and those of the geological class of mixed layer clays. Smectites are particularly montmorillonite (e.g., sodium montmorillonite or calcium montmorillonite), bentonite, pyrophyllite, hectorite, saponite, and soconite ( sauconite, nontronite, talc, beidellite and volchonskoite. Specific kaolins include kaolinite, dickite, nacrite, antigorite, anauxite, halloysite, indellite, and chrysotile. ) includes. Illites include bravaisite, muscovite, paragonite, phlogopite, and biotite. Chlorite may include, for example, corrensite, penninite, donbassite, sudoite, pennine, and clinochlore. . The mixed bed clay may include allevardite and vermiculitebiotite. Modifications and isomorphic substitutions of these layered clays may also be used.

As an optional additive, polishing performance can be further improved by interdispersing nanoparticles (i.e., nanoscale particles) during the supersize coat (e.g., in clay particles). Useful nanoparticles include, for example, nanoparticles of metal oxides such as zirconia, titania, silica, ceria, alumina, iron oxide, vanadia, zinc oxide, antimony oxide, tin oxide, and alumina-silica. Nanoparticles may have a median particle size of at least 1 nanometer, at least 1.5 nanometers, or at least 2 nanometers. The median particle size may be 200 nanometers or less, 150 nanometers or less, 100 nanometers or less, 50 nanometers or less, or 30 nanometers or less.

Other optional ingredients of the supersize composition include curing agents, surfactants, anti-foaming agents, biocides, dispersants and other particulate additives known in the art for use in supersize compositions.

The supersize coat can, in some instances, be formed by providing a supersize composition in which the components are dissolved or otherwise dispersed in a common solvent. In some examples, the solvent is water. After proper mixing, the supersize dispersion can be coated onto an abrasive article and dried to provide a finished supersize coat. If a curing agent is present, the supersize composition can be cured (e.g., hardened) thermally or by exposure to actinic radiation at a wavelength suitable to activate the curing agent.

For example, coating of the supersize composition onto the polishing layer can be performed using any known process. In some examples, the supersize composition is applied by spray coating at constant pressure to achieve a predetermined coating weight. Alternatively, a knife coating method can be used in which the coating thickness is controlled by the gap height of the knife coater.

Some embodiments relate to methods of making articles described herein (e.g., abrasive articles). The method includes a porous backing layer having a first major surface, an opposing second major surface, and a first plurality of pores extending from the first major surface to the second major surface and forming a first pattern, and a second major surface. providing an attachment layer comprising one part of a two-part interconnection attachment mechanism layer adjacent the surface; Disposing a curable abrasive layer having a third major surface and an opposing fourth major surface on the adhesion layer, wherein the first major surface of the adhesion layer is adjacent the third major surface of the curable abrasive layer, and the curable abrasive layer is adjacent to the curable abrasive layer. composition; Abrasive particles at least partially embedded within the curable composition; and a second plurality of voids free of the curable composition and extending from the third major surface to the fourth major surface and forming a second pattern independent of the first pattern; and curing the curable composition to form a cured abrasive layer.

Another method includes an attachment layer comprising a first major surface, an opposing second major surface, and a porous backing layer having a first plurality of pores extending from the first major surface to the second major surface and forming a first pattern. providing a; Disposing a curable abrasive layer having a third major surface and an opposing fourth major surface on the adhesion layer, wherein the first major surface of the adhesion layer is adjacent the third major surface of the curable abrasive layer, and the curable abrasive layer is adjacent to the curable abrasive layer. composition; Abrasive particles at least partially embedded within the curable composition; and a second plurality of voids free of the curable composition and extending from the third major surface to the fourth major surface and forming a second pattern independent of the first pattern; and curing the curable composition to form a cured abrasive layer.

Another method includes a porous backing layer having a first major surface, an opposing second major surface, and a first plurality of pores extending from the first major surface to the second major surface and forming a first pattern, and a second providing an attachment layer comprising one part of a two-part interconnect attachment mechanism layer adjacent the major surface; Disposing a curable abrasive layer having a third major surface and an opposing fourth major surface on the releasable surface of the releasable layer, wherein the curable abrasive layer comprises a curable composition; Abrasive particles at least partially embedded within the curable composition; and a second plurality of voids free of the curable composition and extending from the third major surface to the fourth major surface and forming a second pattern independent of the first pattern; curing the curable abrasive layer to form a cured abrasive layer on the releasable layer; removing the releasable layer; and adhering the cured abrasive layer to an adhesion layer, wherein the first major surface of the adhesion layer is adjacent the third major surface of the abrasive layer.

Another method is an attachment comprising a first major surface, an opposing second major surface, and a porous backing layer having a first plurality of voids extending from the first major surface to the second major surface and forming a first pattern. floor; Disposing a curable abrasive layer on the releasable surface of the releasable layer, wherein the curable abrasive layer comprises a curable composition; Abrasive particles at least partially embedded within the curable composition; and a second plurality of voids free of the curable composition and extending from the third major surface to the fourth major surface and forming a second pattern independent of the first pattern; curing the curable abrasive layer to form a hardened abrasive layer on the releasable layer, wherein the cured abrasive layer has a third major surface and an opposing fourth major surface; removing the releasable layer; and adhering the cured abrasive layer to an adhesion layer, wherein the first major surface of the adhesion layer is adjacent the third major surface of the abrasive layer.

Another method includes a porous backing layer having a first major surface, an opposing second major surface, and a first plurality of voids extending from the first major surface to the second major surface and forming a first pattern, and a second major surface. providing an attachment layer comprising one part of a two-part interconnection attachment mechanism layer adjacent the surface; Disposing a curable layer having a third major surface and an opposing fourth major surface on the releasable surface of the releasable layer, wherein the curable layer comprises: a curable composition; and a second plurality of voids free of the curable composition and extending from the third major surface to the fourth major surface and forming a second pattern independent of the first pattern; laminating the curable layer on the first major surface of the attachment layer; removing the releasable layer; forming a curable abrasive layer by disposing abrasive particles on the curable layer; curing the curable abrasive layer to form a hardened abrasive layer, wherein the abrasive particles are at least partially embedded within the hardened abrasive layer.

Another method is an attachment comprising a first major surface, an opposing second major surface, and a porous backing layer having a first plurality of voids extending from the first major surface to the second major surface and forming a first pattern. providing a layer; Disposing a curable layer having a third major surface and an opposing fourth major surface on the releasable surface of the releasable layer, wherein the curable layer comprises: a curable composition; and a second plurality of voids free of the curable composition and extending from the third major surface to the fourth major surface and forming a second pattern independent of the first pattern; laminating the curable layer on the first major surface of the attachment layer; removing the releasable layer; forming a curable abrasive layer by disposing abrasive particles on the curable layer; curing the curable abrasive layer to form a hardened abrasive layer, wherein the abrasive particles are at least partially embedded within the hardened abrasive layer.

The various methods described herein may further include disposing a size coat on at least one of the curable composition and the cured composition. In some embodiments, a supersize coat can be placed on the size coat.

In some embodiments, the releaseable layer is a release liner. In another embodiment, a porous adhesive layer can be disposed between the first major surface of the attachment layer and the third major surface of the cured abrasive layer. In some examples, the porous adhesive layer allows fluid communication between the attachment layer and the cured abrasive layer.

As used herein, the term “alkyl” refers to an alkyl group having 1 to 40 carbon atoms (C ₁ to C ₄₀ ), 1 to about 20 carbon atoms (C ₁ -C ₂₀ ), 1 to 12 carbon atoms (C ₁ -C ₁₂ ), refers to straight-chain and branched alkyl groups having 1 to 8 carbon atoms (C ₁ -C ₈ ), or, in some embodiments, 3 to 6 carbon atoms (C ₃ to C ₆ ). Examples of straight chain alkyl groups include those having 1 to 8 carbon atoms, such as methyl, ethyl, n-propyl, n-butyl, n-pentyl, n-hexyl, n-heptyl, and n-octyl groups. do. Examples of branched alkyl groups include, but are not limited to, isopropyl, iso-butyl, sec-butyl, t-butyl, neopentyl, isopentyl, and 2,2-dimethylpropyl groups.

As used herein, the term "alkoxy" refers to the group -O-alkyl, where "alkyl" is defined herein.

As used herein, the term “aryl” refers to a cyclic aromatic hydrocarbon that contains no heteroatoms in the ring. Thus, aryl groups include phenyl, azulenyl, hepthalenyl, biphenyl, indacenyl, fluorenyl, phenanthrenyl, triphenylenyl, pyrenyl, naphthacenyl, chrysenyl, biphenylenyl, anthracenyl, and naphenyl. Includes, but is not limited to, a til group. In some embodiments, an aryl group contains from about 6 to about 14 carbons (C ₆ to C ₁₄ ) or 6 to 10 carbon atoms (C ₆ to C ₁₀ ) in the ring portion of the group.

As used herein, the term “about” refers to the degree of variation in a given value or range, e.g., within 10%, within 5%, or within 1% of the limits of the stated value or stated range. It is permissible.

Unless otherwise specified herein, as used herein, the term “substantially” means at least about 50%, 60%, 70%, 80%, 90%, 95%, 96%, 97%, 98%. refers to the majority or majority, as in %, 99%, 99.5%, 99.9%, 99.99%, or at least about 99.999% or more.

Unless otherwise specified herein, as used herein, the term “substantially not” means less than about 10%, 5%, 2%, 1%, 0.5%, 0.01%, 0.001%, or about 0.0001%. As in % below, it refers to not a minority or majority.

A value expressed in range format includes all individual numeric values or subranges contained within that range, as well as the numeric values explicitly stated as limits of that range, as if each numeric value and subrange were It should be interpreted in a flexible manner as including as explicitly stated. For example, a range of “about 0.1% to about 5%” or “about 0.1% to 5%” includes not only about 0.1% to about 5%, but also individual values within the indicated range (e.g., 1%, 2%, 3%, and 4%) and subranges (e.g., 0.1% to 0.5%, 1.1% to 2.2%, 3.3% to 4.4%). Unless otherwise indicated, reference to “about X to Y” has the same meaning as “about X to about Y.” Likewise, unless otherwise indicated, reference to “about X, Y, or about Z” has the same meaning as “about X, about Y, or about Z.”

As used herein, the singular terms “a”, “an”, or “the” are used to include one or more than one, unless the context clearly indicates otherwise. The term “or” is used to refer to the non-exclusive “or” unless otherwise indicated. Moreover, it is to be understood that phrases or terms used herein and not otherwise defined are for purposes of description only and not of limitation. Any use of section headings is intended to aid understanding of the document and should not be construed as limiting. Additionally, information related to the section title may be within or outside of that specific section. In addition, all publications, patents, and patent documents mentioned herein are herein incorporated by reference in their entirety as if individually incorporated by reference. In the event of any inconsistency between the use of this specification and the documents so incorporated by reference, the use in the incorporated reference should be considered as supplementary to the use of this specification; In case of irreconcilable inconsistency, usage herein will govern.

In the methods described herein, the steps may be performed in any order without departing from the principles of the invention, except where the chronological or operational sequence is explicitly stated. Moreover, specified steps may be performed simultaneously, unless the explicit language of the claims indicates that they are to be performed separately. For example, the claimed steps of doing X and the claimed steps of doing Y could be performed simultaneously within a single operation and the resulting process would fall within the literal scope of the claimed process.

Selected embodiments of the invention include, but are not limited to:

In a first embodiment, the present invention:

a porous backing layer having a first major surface, an opposing second major surface, and a first plurality of voids extending from the first major surface to the second major surface and forming a first pattern; and

One part of the two-part interconnection attachment mechanism layer adjacent the second major surface.

An adhesion layer comprising; and

having a third major surface and an opposing fourth major surface;

cured composition;

abrasive particles at least partially embedded within the cured composition; and

a second plurality of voids free of cured composition and extending from the third major surface to the fourth major surface and forming a second pattern independent of the first pattern;

abrasive layer containing

Includes,

The first major surface of the adhesion layer is adjacent the third major surface of the abrasive layer, providing an abrasive article.

In a second embodiment, the present invention:

an adhesion layer comprising a first major surface, an opposing second major surface, and a porous backing layer having a first plurality of voids extending from the first major surface to the second major surface and forming a first pattern; and

having a third major surface and an opposing fourth major surface;

cured composition;

abrasive particles at least partially embedded within the cured composition; and

a second plurality of voids free of cured composition and extending from the third major surface to the fourth major surface and forming a second pattern independent of the first pattern;

A continuous polishing layer comprising

Includes,

The first major surface of the adhesion layer is adjacent the third major surface of the abrasive layer, providing an abrasive article.

In a third embodiment, the invention provides an abrasive article according to the second embodiment, wherein the attachment layer includes one part of a two-part interconnection attachment mechanism integral to the porous backing layer.

In a fourth embodiment, the invention provides an abrasive article according to the second embodiment, wherein the attachment layer includes one part of a two-part interconnection attachment mechanism layer adjacent the second major surface.

In a fifth embodiment, the invention provides any one of the first, third and fourth embodiments, wherein one part of the two-part interconnection attachment mechanism includes at least one of a hook and a loop. Provides abrasive articles according to.

In a sixth embodiment, the invention provides an abrasive article according to any one of the first to fifth embodiments, wherein the abrasive layer covers no more than 98% of the first major surface of the adhesion layer.

In a seventh embodiment, the invention provides any one of the first to sixth embodiments, wherein the surface topography of the fourth major surface of the polishing layer is independent of the topography of the first major surface of the adhesion layer. Provides abrasive articles according to shape.

In an eighth embodiment, the present invention relates to any one of the first to seventh embodiments, wherein the cured composition includes at least one of a cured epoxy-acrylate resin composition and a cured phenolic resin composition. Provides abrasive products according to the requirements.

In a ninth embodiment, the present invention provides a cured composition comprising at least one tetrahydrofurfuryl (THF) (meth)acrylate copolymer component; One or more epoxy resins; and a polymerized epoxy-acrylate resin composition comprising at least one hydroxy-functional polyether.

In a tenth embodiment, the present invention provides an abrasive article according to any one of the first to ninth embodiments, wherein the cured composition further comprises one or more photoinitiators.

In an eleventh embodiment, the present invention provides an abrasive article according to any one of the first to tenth embodiments, wherein the abrasive particles include shaped abrasive particles.

In a twelfth embodiment, the present invention is according to any one of the first to eleventh embodiments, further comprising at least one of a size coat and a supersize coat positioned adjacent the fourth major surface. Provides abrasive supplies.

In a thirteenth embodiment, the present invention provides the method of the first to twelfth embodiments, wherein air flows through the article at a velocity of at least 1.0 L/s such that dust can be removed through the abrasive article from the polished surface when in use. An abrasive article according to any one of the embodiments is provided.

In a fourteenth embodiment, the invention further comprises a porous adhesive layer disposed between the first major surface of the adhesion layer and the third major surface of the polishing layer, wherein the porous adhesive layer is disposed between the adhesive layer and the cured abrasive layer. Provided is an abrasive article according to any one of the first to thirteenth embodiments, which enables fluid communication.

In a fifteenth embodiment, the present invention provides a method of making an abrasive article, the method comprising:

a porous backing layer having a first major surface, an opposing second major surface, and a first plurality of voids extending from the first major surface to the second major surface and forming a first pattern; and

One part of the two-part interconnection attachment mechanism layer adjacent the second major surface.

providing an adhesion layer comprising;

Disposing a curable abrasive layer having a third major surface and an opposing fourth major surface on the adhesion layer, wherein the first major surface of the adhesion layer is adjacent the third major surface of the curable abrasive layer,

curable composition;

Abrasive particles at least partially embedded within the curable composition; and

a second plurality of voids free of curable composition and extending from the third major surface to the fourth major surface and forming a second pattern independent of the first pattern;

Contains -; and curing the curable composition to form a cured abrasive layer.

In a sixteenth embodiment, the present invention provides a method of making an abrasive article, the method comprising:

Providing an adhesion layer comprising a first major surface, an opposing second major surface, and a porous backing layer having a first plurality of pores extending from the first major surface to the second major surface and forming a first pattern. ;

Disposing a curable abrasive layer having a third major surface and an opposing fourth major surface on the adhesion layer, wherein the first major surface of the adhesion layer is adjacent the third major surface of the curable abrasive layer,

curable composition;

Abrasive particles at least partially embedded within the curable composition; and

a second plurality of voids free of curable composition and extending from the third major surface to the fourth major surface and forming a second pattern independent of the first pattern;

Contains -; and curing the curable composition to form a cured abrasive layer.

In a seventeenth embodiment, the present invention provides a method of making an abrasive article, the method comprising:

a porous backing layer having a first major surface, an opposing second major surface, and a first plurality of voids extending from the first major surface to the second major surface and forming a first pattern; and

One part of the two-part interconnection attachment mechanism layer adjacent the second major surface.

providing an adhesion layer comprising;

disposing a curable abrasive layer having a third major surface and an opposing fourth major surface on the releasable surface of the releasable layer, wherein the curable abrasive layer

curable composition;

Abrasive particles at least partially embedded within the curable composition; and

a second plurality of voids free of curable composition and extending from the third major surface to the fourth major surface and forming a second pattern independent of the first pattern;

Contains -;

curing the curable abrasive layer to form a cured abrasive layer on the releasable layer;

removing the releasable layer; and

and adhering the cured abrasive layer to an adhesion layer, wherein the first major surface of the adhesion layer is adjacent the third major surface of the abrasive layer.

In an eighteenth embodiment, the present invention provides a method of making an abrasive article, the method comprising:

Providing an adhesion layer comprising a first major surface, an opposing second major surface, and a porous backing layer having a first plurality of pores extending from the first major surface to the second major surface and forming a first pattern. ;

Disposing a curable abrasive layer on the releasable surface of the releasable layer, wherein the curable abrasive layer is

curable composition;

Abrasive particles at least partially embedded within the curable composition; and

a second plurality of voids free of curable composition and extending from the third major surface to the fourth major surface and forming a second pattern independent of the first pattern;

Contains -;

curing the curable abrasive layer to form a hardened abrasive layer on the releasable layer, wherein the cured abrasive layer has a third major surface and an opposing fourth major surface;

removing the releasable layer; and

and adhering the cured abrasive layer to an adhesion layer, wherein the first major surface of the adhesion layer is adjacent the third major surface of the abrasive layer.

In a 19th embodiment, the present invention provides a method of making an abrasive article, the method comprising:

a porous backing layer having a first major surface, an opposing second major surface, and a first plurality of voids extending from the first major surface to the second major surface and forming a first pattern; and

One part of the two-part interconnection attachment mechanism layer adjacent the second major surface.

providing an adhesion layer comprising;

disposing a curable layer having a third major surface and an opposing fourth major surface on the releasable surface of the releasable layer, wherein the curable layer

curable composition; and

a second plurality of voids free of curable composition and extending from the third major surface to the fourth major surface and forming a second pattern independent of the first pattern;

Contains -;

laminating the curable layer on the first major surface of the attachment layer;

removing the releasable layer;

forming a curable abrasive layer by disposing abrasive particles on the curable layer; and

curing the curable abrasive layer to form a hardened abrasive layer, wherein the abrasive particles are at least partially embedded within the hardened abrasive layer.

In a twentieth embodiment, the present invention provides a method of making an abrasive article, the method comprising:

Providing an adhesion layer comprising a first major surface, an opposing second major surface, and a porous backing layer having a first plurality of pores extending from the first major surface to the second major surface and forming a first pattern. ;

disposing a curable layer having a third major surface and an opposing fourth major surface on the releasable surface of the releasable layer, wherein the curable layer

curable composition; and

a second plurality of voids free of curable composition and extending from the third major surface to the fourth major surface and forming a second pattern independent of the first pattern;

Contains -;

laminating the curable layer on the first major surface of the attachment layer;

removing the releasable layer;

forming a curable abrasive layer by disposing abrasive particles on the curable layer; and

curing the curable abrasive layer to form a hardened abrasive layer, wherein the abrasive particles are at least partially embedded within the hardened abrasive layer.

In a twenty-first embodiment, the invention provides the method of any one of the sixteenth, eighteenth, and twentieth embodiments, wherein the attachment layer comprises one part of a two-part interconnection attachment mechanism that is integral to the porous backing layer. A method of manufacturing an abrasive article according to an embodiment is provided.

In a twenty-second embodiment, the invention provides any of the sixteenth, eighteenth, and twentieth embodiments, wherein the attachment layer includes one part of a two-part interconnection attachment mechanism layer adjacent the second major surface. A method of making an abrasive article according to one embodiment is provided.

In a twenty-third embodiment, the invention provides the fifteenth, seventeenth, nineteenth, twenty-first embodiments, wherein one part of the two-part interconnection attachment mechanism includes at least one of a hook and a loop. and a method of manufacturing an abrasive article according to any one of the twenty-second embodiments.

In a twenty-fourth embodiment, the present disclosure provides a method of making an abrasive article according to any one of the seventeenth through twenty-third embodiments, wherein the releasable layer is a release liner.

In a twenty-fifth embodiment, the present invention provides an abrasive article according to any one of the fifteenth to twenty-fourth embodiments, wherein the curable composition comprises at least one of a curable epoxy-acrylate resin composition and a phenolic resin composition. A manufacturing method is provided.

In a twenty-sixth embodiment, the present invention provides a curable composition comprising at least one tetrahydrofurfuryl (THF) (meth)acrylate copolymer component; One or more epoxy resins; and a polymerizable epoxy-acrylate resin composition comprising at least one hydroxy-functional polyether.

In a twenty-seventh embodiment, the present invention provides a method of making an abrasive article according to any one of the fifteenth through twenty-sixth embodiments, wherein the curable composition further comprises one or more photoinitiators.

In a twenty-eighth embodiment, the present invention provides a method of making an abrasive article according to any one of the fifteenth through twenty-seventh embodiments, wherein the abrasive particles include shaped abrasive particles.

In a twenty-ninth embodiment, the invention provides a method of making an abrasive article according to any one of the fifteenth through twenty-eighth embodiments, wherein the abrasive layer covers no more than 98% of the first major surface of the adhesion layer. do.

In a thirtieth embodiment, the present invention provides any of the fifteenth to twenty-ninth embodiments, wherein the surface topography of the fourth major surface of the polishing layer is independent of the topography of the first major surface of the adhesion layer. A method of manufacturing an abrasive article according to shape is provided.

In a thirty-first embodiment, the invention further comprises a porous adhesive layer disposed between the first major surface of the adhesion layer and the third major surface of the cured abrasive layer, wherein the porous adhesive layer is connected to the adhesive layer and the cured abrasive layer. A method of manufacturing an abrasive article according to any one of the fifteenth to thirtieth embodiments is provided, enabling fluid communication between layers.

In a thirty-second embodiment, the invention provides the method of any one of the fifteenth through thirty-first embodiments, wherein the abrasive article further comprises at least one of a size coat and a supersize coat positioned adjacent the fourth major surface. A method of manufacturing an abrasive article according to shape is provided.

Example

The examples described herein are intended to be illustrative only rather than predictive, and changes in manufacturing and testing procedures may yield different results. All quantitative values in the examples section are to be understood as approximations in light of the generally known tolerances involved in the procedures used. The foregoing detailed description and examples are provided solely for clarity of understanding. It should be understood that there are no unnecessary limitations therefrom.

Examples are described using the following abbreviations:

℃: degrees Celsius

cm: centimeter

cm/min: centimeters per minute

g/eq.: gram equivalent

g/m ² : gram/square meter

in/min: inches per minute

kg: kilogram

lb: pound

MFFT: Minimum film formation temperature

min: minute;

μ-inch: 10 ^-6 inches

mm: millimeters

μm: micrometer

L/s: liter per second

m/min: meters per minute

mW/cm2: milliwatt/square centimeter

N: newton

N-mm: newton-millimetre

N/m ² : newton/square meter

pbw: parts by weight

rpm: revolutions per minute

T _g : glass transition temperature

UV: ultraviolet rays

W/cm2: watt per square centimeter

wt.%: weight percent

Unless otherwise stated, all reagents are obtained or are available from chemical distributors, such as Sigma-Aldrich Company, St. Louis, Missouri, or can be synthesized by known methods. Unless otherwise noted, all ratios are on a dry weight basis.

Abbreviations for materials and reagents used in the examples are as follows:

CM-5: Fumed silica obtained from Cabot Corporation, Boston, MA, under the trade designation “CAB-O-SIL M-5”.

CPI-6976: Triarylsulfonium hexafluoroantimonate/propylene carbonate photoinitiator obtained from Dow Chemical Company, Midland, MI, USA under the trade name “Cyracure CPI 6976”.

D-1173: α-hydroxyketone photoinitiator obtained under the trade name “Darocur 1173” from BASF Corporation, Florham Park, NJ.

I-819: Bis-acyl phosphine photoinitiator obtained from BASF Corporation under the trade name “Irgacure 819”.

MX-10: Sodium-potassium alumina silicate filler obtained under the trade name “Minex 10” from The Carey Company, Addison, IL.

P80: Grade 80 aluminum oxide mineral obtained from Treibacher Industrie AG, Aaltofen, Austria under the trade name "BFRPL".

80+ Mineral Blend: A 90:10 weight percent blend of P80 and 80+ fine grain minerals obtained from 3M Company, St. Paul, MN under the trade designation "Cubitron II".

P320: A 320 grade aluminum oxide mineral obtained from Treivacher Industry AG, Aaltofen, Austria under the trade name "BFRPL".

SR-351: Trimethylol propane triacrylate available from Sartomer USA, LLC, Exton, PA under the trade designation “SR351”.

UVR-6110: 3,4-epoxy cyclohexylmethyl-3,4-epoxy cyclohexylcarboxylate obtained from Daicel Chemical Industries, Ltd., Tokyo, Japan.

W-985: Acidic polyester surfactant obtained from BYK-Chemie GmbH, Wesel, Germany under the trade name “BYK W-985”.

ARCOL: Polyether polyol obtained from Bayer Material Sciences, LLC, Pittsburgh, PA, under the trade name “ARCOL LHT 240”.

BA: Butyl acrylate obtained from BASF Corporation, Florham Park, NJ, USA.

E-1001F: diglycidyl ether of bisphenol-A epoxy resin, obtained from Momentive Specialty Chemicals, Inc. under the trade name "Epon 1001F".

E-1510: Bisphenol-A epoxy resin with an epoxy equivalent weight of 210 to 220 g/eq, obtained from Momentive Specialty Chemicals, Inc. under the trade designation "Eponex 1510".

GPTMS: 3-(glycidoxypropyl) trimethoxysilane obtained from United Chemical Technologies, Inc., Bristol, PA.

I-651: Benzyldimethyl ketal photoinitiator obtained from BASF Corporation under the trade name “Irgacure 651”.

IOTG: Isooctyl thioglycolate obtained from Evans Chemetics, LP, Teaneck, NJ.

LVPREN: Ethylene-vinyl acetate copolymer obtained from Lanxess Corporation, Pittsburgh, PA, under the trade name “Levaprene 700 HV”.

PKHA: Phenoxy resin obtained under the trade name “PHENOXY PKHA” from Inchem Corporation, Rock Hill, SC.

THFA: Tetrahydrofurfuryl acrylate, V-150, obtained from San Esters Corporation, New York, NY, USA.

Mesh backing 1: Polyester/polyamide net backing available under the trade name “NET MESH” from Sitip S.p.A., Via Val Lata, CENE (BG), Italy 13-24030.

polishing test

The samples were subjected to the following polishing tests. A 6 inch (15.24 cm) diameter abrasive disk was mounted on a 6 inch (15.24 cm) diameter, 25 hole, backup pad, part number “05865,” obtained from 3M Company. This assembly was then assembled into a printed test panel measuring 18 × 24 inches (45.72 × 60.96 cm) (part number “59597” from ACT Test Panels LLC, Hillsdale, MI). (available) was fixed to the X-Y table and attached to a dual action sander placed on the table. The dual-action sander was maintained at 2.5 degrees and driven electrically at a speed of 5400 rpm. The sander was applied to the painted panel using a downward force of 13 lb (5.91 kg). The sander was used in a side-to-side sweeping motion, starting from the lower right corner of the panel and indexing upward after each sweep, so that the entire panel was sanded in 1 minute, with a total of 7 passes of the DA sander. The mass of the panel was measured before and after each cycle to determine the total mass loss in grams for each 1 minute cycle, as well as the cumulative mass loss at the end of three cycles. Cutting life was measured by dividing the third pass weight loss by the first pass weight loss. Each sample was tested in duplicate, and the average of the results is reported in Table 1.

pressure drop test

For Example 3, Comparative Example A and Comparative Example B, the pressure drop across each sample was measured at constant air flow rate. A 1.2 inch (30.5 mm) x 1.4 inch (35.6 mm) sample was used for each measurement. For Comparative Example A, the sample was taken just outside the center hole of the abrasive disc. For each pressure drop measurement, the sample was held between two identical plastic frames, exposing an area of 1 inch (25.4 mm) by 1 inch (25.4 mm) in the center of the frames. The frame/sample assembly was inserted into a square duct with internal dimensions of 1 inch (2.54 cm) by 1 inch (2.54 cm) such that the plane of the sample was perpendicular to the direction of air flow within the duct. The air flow into the duct was controlled by a regulator such that a constant linear velocity of 3.82 m/s flowed through each sample. Ports were placed in the duct equidistant from the sample, one in front and one behind the sample. The ports were connected to a differential pressure gauge and the pressure drop was recorded for each sample. The results of these tests are shown in Table 2.

Tensile force test at break

The tensile force required to break the abrasive strip was measured for all of Example 3, Comparative Example A, Comparative Example C, Comparative Example D, and Comparative Example E. Tensile testing was performed on an MTS ALLIANCE RT5 testing machine manufactured by MTS Systems Corporation, Cary, NC. For each test, a 1 inch (25.4 mm wide) by 5 inches (127 mm) abrasive strip was clamped in the clamps of the testing machine, such that 2 inches (50.8 mm) of the sample was exposed between the clamps. The sample was stretched at a rate of 50.8 mm/min and the breaking force was recorded. The test was repeated for a total of five measurements per sample, and the average results are shown in Table 3.

Surface topography test

Example 3, Comparative Example B and The surface topography, or height profile, of mesh backing 1 (used in the fabrication of Example 3) was determined. The "Measure > Profile" function was used across a straight line of abrasive-coated material to collect surface topography data along that line. The data were then normalized and graphed; The results are shown in Figure 8.

Preparation of Make Resin 1 (MR1)

Charge 387.8 grams UVR-6110, 166.2 grams SR-351, and 6.0 grams W-985 into a 32 oz. (0.95 liter) black plastic container and disperse using a high-speed mixer at 70°F (21.1°C) for 5 minutes. I ordered it. With continued stirring, 400.0 grams of MX-10 was added slowly over approximately 15 minutes. 30.0 grams of CPI-6976 and 10.0 grams of I-819 were added to the resin and dispersed until homogeneous, approximately 5 minutes. Finally, 16 grams of CM-5 was added slowly over approximately 15 minutes until homogeneously dispersed.

Preparation of size resin 1 (SR1)

Charge 1008.0 grams of UVR-6110 and 432.0 grams of SR-351 into a 128 oz. (3.79 liter) black plastic container and mix for 5 minutes at 70°F (21.1°C) using a high-speed mixer equipped with a Cowles blade. Disperse for minutes. With continued agitation, 45.0 grams of CPI-6976 and 15.0 grams of D-1173 were added to the resin and dispersed until homogeneous, approximately 5 minutes.

Preparation of Acrylic Copolymer 1 (AC1)

Acrylic copolymer 1 was prepared by the method of US Patent No. 5,804,610 (Hamer et al.). A solution was prepared by combining 50 parts by weight (pbw) BA, 50 pbw THFA, 0.2 pbw I-651, and 0.1 pbw IOTG in an amber glass bottle and mixing by hand swirling. The solution was placed in 25 gram aliquots into heat-sealed compartments of ethylene vinyl acetate-based film, immersed in a 16°C water bath, and polymerized using UV light (UVA = 4.7 mW cm 2, 8 minutes per side).

Preparation of high temperature melt resin 1 (HM1)

A BRABENDER mixer (C.W. Brabender Instruments, Inc., Hackensack, NJ, USA) equipped with a 50 gram capacity heated mixing head and kneading element was used. A high-temperature melt make resin composition (HM1) was prepared. The mixer was operated at the desired mixing temperature of 120° C., and the kneading element was operated at 100 rpm. First, AC1 (32 pbw) was added and mixed for several minutes. E -1001 F (19 pbw), LVPREN (10 pbw), and PKHA (10 pbw) were added and mixed until evenly distributed throughout the mixture. E-1510 (19 pbw), ARCOL (10 pbw) , and GPTMS (1 pbw) were premixed and then added slowly until evenly distributed.The resulting mixture was stirred for several minutes and then the photoacid generator (CPI-6976, 0.5 pbw) was added dropwise.Mixture was stirred for a few minutes, then transferred to an aluminum pan and left to cool (care was taken to protect against ambient light exposure).

Example 1

A 31 inch × 23 inch (78.74 × 58.42 cm) stencil of 5 mil (127.0 μm) thick polyester film was fabricated in a zig zag pattern, with each zigzag having a wavelength of 1 inch (25.4 mm). and 0.25 inches wide (6.4 mm), spaced 80 mils (2.0 mm) apart, with a maximum amplitude of 1 inch. Patterns were cut into the polyester film using an EAGLE MODEL 500 W CO2 laser obtained from Preco Laser, Inc., Somerset, WI. The resulting stencil was taped tautly to an aluminum frame measuring 23 × 31 inches.

The aluminum frame stencil was placed on a 12 inch × 20 inch (30.48 × 50.8 cm) piece of mesh backing 1. Approximately 75 grams of MR1 was spread onto the mesh manually at 70°F (21.1°C) using a urethane squeegee and subsequently printed onto the mesh backing without penetrating into the back of the mesh. The stencil was removed from the backing. Approximately 20 grams of the 80+ mineral blend was spread evenly onto a 14 x 20 inch (35.56 x 50.8 cm) plastic mineral tray to create a mineral bed. The mineral tray was then inserted into the base of a custom-built mineral coater by 3M Company, Maplewood, MN. The resin-coated mesh backing is suspended 1 inch (25.4 mm) above the mineral bed (resin exposed), and the mineral is electrostatically electrolyzed by applying 20 to 25 kilovolts of DC across the metal plate and the resin-coated mesh backing. It was transferred to the resin surface. Using two V-bulbs operating sequentially at 400 W/in (157.5 W/cm) and a web speed of 40 ft/min (12.19 m/min), corresponding to a total dose of approximately 894 mJ/cm2, The samples were cured by one pass through a UV processor available from American Ultraviolet Company, Murray Hill, NJ, and then thermally cured at 284°F (140°C) for 5 minutes.

Weigh the SR1 using a No. 90 Mayer Rod and kiss coat it using a roll coater at 70°F (21.1°C) and approximately 5 m/min to avoid clogging the dust extraction holes. SR1 was applied over the mineral coated area of the sheet. A roll coater with a steel top roller and a 90 Shore A durometer rubber bottom roller was obtained from Eagle Tool, Inc., Minneapolis, MN. UV using two V-bulbs operating sequentially at 400 W/in (157.5 W/cm) and a web speed of 40 ft/min (12.19 m/min), corresponding to a total dose of approximately 894 mJ/cm2. The article was cured by passing it once through the processor and then thermally cured at 284°F (140°C) for 5 minutes.

Example 2

MR1 was applied in a wavy pattern on mesh backing 1 using the 2-roll coater described in Example 1. Using a No. 90 Meyer rod, MR1 was weighed onto a transfer roll rotating at 5 m/min, followed by a notched trowel (Roberts #49737, 3 mm × 3 mm × 1.5 mm V notch). , available from Home Depot, Inc.) was pressed against a rubber transfer roll and manually vibrated from side to side to create a wavy pattern in the resin, which was transferred to the mesh backing.

Approximately 20 grams of the 80+ mineral blend was spread evenly onto a 14 x 20 inch (35.56 x 50.8 cm) plastic mineral tray to create the mineral bed. The mineral tray was then inserted into the base of a custom-built mineral coater by 3M Company, Maplewood, MN. The resin-coated mesh backing is suspended 1 inch (25.4 mm) above the mineral bed (resin exposed), and the mineral is electrostatically electrolyzed by applying 20 to 25 kilovolts of DC across the metal plate and the resin-coated mesh backing. It was transferred to the resin surface. Using two V-bulbs operating sequentially at 400 W/in (157.5 W/cm) and a web speed of 40 ft/min (12.19 m/min), corresponding to a total dose of approximately 894 mJ/cm2, The samples were cured by one pass through a UV processor available from American Ultra Violet Company, Murray Hill, NJ, and then thermally cured at 284°F (140°C) for 5 minutes.

Metering the size resin using a No. 90 Meyer rod, at 70°F (21.1°C) and approximately 5 m/min, kiss-coat using a roll coater onto the mineral-coated area of the sheet to avoid clogging the dust extraction holes. SR1 was applied throughout. The roll coater with a steel upper roller and a 90 Shore A durometer rubber lower roller was obtained from Eagle Tools, Inc., Minneapolis, MN. UV using two V-bulbs operating sequentially at 400 W/in (157.5 W/cm) and a web speed of 40 ft/min (12.19 m/min), corresponding to a total dose of approximately 894 mJ/cm2. The article was cured by passing it once through the processor and then thermally cured at 284°F (140°C) for 5 minutes.

Example 3

A 3 mil thick film (76 μm) of HM1 at 120°C was cast onto a patterned tool to create evenly spaced oval openings (2.5 mm × 1.6 mm holes with hexagonal packing and 20% open area) of HM1. A patterned film was prepared and placed on mesh backing 1.

Approximately 5 grams of P320 mineral was spread evenly onto a 14 x 20 inch (35.56 x 50.8 cm) plastic mineral tray to create the mineral bed. The mineral tray was then inserted into the base of a custom-built mineral coater by 3M Company, Maplewood, MN. The resin-coated mesh backing is suspended 1 inch (25.4 mm) above the mineral bed (resin exposed), and the mineral is electrostatically electrolyzed by applying 20 to 25 kilovolts of DC across the metal plate and the resin-coated mesh backing. It was transferred to the resin surface. Using two V-bulbs operating sequentially at 400 W/in (157.5 W/cm) and a web speed of 40 ft/min (12.19 m/min), corresponding to a total dose of approximately 894 mJ/cm2, The samples were cured by one pass through a UV processor available from American Ultra Violet Company, Murray Hill, NJ, and then thermally cured at 284°F (140°C) for 5 minutes.

Metering the size resin using a No. 90 Meyer rod, at 70°F (21.1°C) and approximately 5 m/min, kiss-coat using a roll coater onto the mineral-coated area of the sheet to avoid clogging the dust extraction holes. SR1 was applied throughout. The roll coater with a steel upper roller and a 90 Shore A durometer rubber lower roller was obtained from Eagle Tools, Inc., Minneapolis, MN. UV using two V-bulbs operating sequentially at 400 W/in (157.5 W/cm) and a web speed of 40 ft/min (12.19 m/min), corresponding to a total dose of approximately 894 mJ/cm2. The article was cured by passing it once through the processor and then thermally cured at 284°F (140°C) for 5 minutes.

Comparative Example A (CE-A)

A 6-inch (15.24 cm) loop-backed abrasive disc available from 3M Company, St. Paul, Minnesota, under the trade designation “P320 334U.”

Comparative Example B (CE-B)

6-inch (15.24 cm) loop-backed abrasive discs available from KWH Mirka, Finland under the trade designation "P320 Abranet".

Comparative Example C (CE-C)

A 6-inch (6-inch 15.24 cm) loop-backed abrasive disc.

Comparative Example D (CE-D)

6-inch (15.24 cm) loop-backed film available under the trade designation "P320 SUNMIGHT FILM 9-HOLE" from Sunmight USA Corp., La Mirada, CA. Abrasive disc.

Comparative Example E (CE-E)

A 6-inch (15.24 cm) loop-backed abrasive disc available from Sia Abrasives USA, Lincolnton, NC, under the trade name “P320 SIAFAST ABRASIVE.”

Example 3, Comparative Example A and Comparative Example B were evaluated using polishing tests. The results are shown in Table 1.

[Table 1]

Example 3, Comparative Example A and Comparative Example B were evaluated using pressure drop testing. The results are shown in Table 2.

[Table 2]

Example 3, Comparative Example A, Comparative Example C, Comparative Example D, and Comparative Example E were evaluated using the tensile force at break test. The results are shown in Table 3.

[Table 3]

It will be apparent to those skilled in the art that the specific structures, features, details, configurations, etc. disclosed herein are merely examples that can be modified and/or combined in multiple embodiments. All such modifications and combinations are considered by the inventor to be within the scope of the present invention. Accordingly, the scope of the invention should not be limited to the specific example structures described herein, but rather extends to at least the structures described by the language of the claims and equivalents of such structures. In case of conflict or inconsistency between this specification as written and the disclosure of any document incorporated herein by reference, the specification as written will control. In addition, all publications, patents, and patent documents mentioned herein are incorporated by reference in their entirety as if fully set forth herein.

Claims (25)

an adhesion layer comprising a first major surface, an opposing second major surface, and a porous backing layer having a first plurality of voids extending from the first major surface to the second major surface and forming a first pattern; and
having a third major surface and an opposing fourth major surface;
cured composition;
abrasive particles at least partially embedded within the cured composition; and
a second plurality of voids free of cured composition and extending from the third major surface to the fourth major surface and forming a second pattern independent of the first pattern;
abrasive layer containing
Includes,
An abrasive article, wherein the first major surface of the adhesion layer is adjacent the third major surface of the abrasive layer. The abrasive article of claim 1 , wherein the attachment layer comprises one part of a two-part interconnect attachment mechanism integral to the porous backing layer. The abrasive article of claim 1 , wherein the attachment layer comprises one part of a two-part interconnect attachment mechanism layer adjacent the second major surface. The abrasive article of claim 1 , wherein the surface topography of the fourth major surface of the abrasive layer is independent of the topography of the first major surface of the adhesion layer. 4. An abrasive article according to any preceding claim, wherein air flows through the article at a rate of at least 1.0 L/s so that dust can be removed through the abrasive article from the abraded surface when in use. 4. The method of any one of claims 1 to 3, further comprising a porous adhesive layer disposed between the first major surface of the attachment layer and the third major surface of the polishing layer, wherein the porous adhesive layer is cured with the attachment layer. An abrasive article that allows fluid communication between the abrasive layers. Providing an adhesion layer comprising a first major surface, an opposing second major surface, and a porous backing layer having a first plurality of pores extending from the first major surface to the second major surface and forming a first pattern. ;
Disposing a curable abrasive layer having a third major surface and an opposing fourth major surface on the adhesion layer, wherein the first major surface of the adhesion layer is adjacent the third major surface of the curable abrasive layer,
curable composition;
Abrasive particles at least partially embedded within the curable composition; and
a second plurality of voids free of curable composition and extending from the third major surface to the fourth major surface and forming a second pattern independent of the first pattern;
Contains -; and
curing the curable composition to form a cured abrasive layer.
A method of manufacturing an abrasive article, comprising: delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete

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